Refractories and Kilns - for the Self-Reliant Potter

Henrik Norsker I The Self-Reliant Potter: Refractories and Kilns Vieweg Deutsches Zcntrum fik Entwicklungstechnolo...

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Henrik Norsker

I

The Self-Reliant Potter: Refractories and Kilns

Vieweg

Deutsches Zcntrum

fik Entwicklungstechnologien

- GATE

Deutsches Zentrum fiir Ent\U&mgstechnologien GATE stands for German Appropriate Technology Exchange. It was founded in 197Xas a special division of’ the Deutschc Gesellschafi fiir Technische Zusammenurbeit fC;TZ) GmbH. GATE is a centre for the dissemination and promotion of appropriate technologies for developing countries. GATE defines ..Appropriate technologies” as those which are suitable and acceptable in the light of economic. social and cultural criteria. They should contribute to socio-economic development Lvhilst ensuring optimal utilktion of resources and minima! detriment to the environment. Depending on the caseat hand ;I traditional. intermediate or highly-devclopcd can be the ,.approprinte” one. GATE focussesits work on three key areas: - Twh~~~/r~~~~~ fklr~ur~~~~: Collecting. processing and disseminating inf’ormation on technologies appropriate to the needs of the developing countries; asctxtaining the technologiciil requirements of Third World countries: support in the form of personnel, material ;rnd eqcipmont to promote the development and adaptation of technologies tix developing countries. Rr.wtrrc*h ml/

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work in approyri;tic rxhnologies. (‘f~optwlicdr itr ?;~c~lttrokt.~rc.~rl I~c~lr~lc~~ttttc~tt~.~ C’cN:iXJrilti~~fl in the I’txm 0f’Jolnt projects \\.ith relevant institutions in developing countries and in the l-‘e:JcruIRcpuhlic 1>1’ CkrllliIn>. GATE HIS !XX~ itI iIcti\.e supporter ofthc SATIS network (Socii~ll~ApproFor scvcrd years priate Technology Information Services)ittld has entcrcd into cooperiiticln qrcements with ;I number of’ technology centres in Third World countries. C;A’!X of’t’ersit free information serviceon appropriilte technoiogks for ii11 public and priviltc dwelopment institutions in dewloping countries. dealing with the development. ildapt;ition, introduction and upplic:~tion of technologies.

Deutsche Cesellschaft

fiir Tcchsische Zusammenarbeit

(CTZ)

GmbH

The povernment-owned (;‘T% operates in the Iicld of Technical C’oupcri~tkln. 2 200 (krman evpcrts ;Ire \\orking together with partners I‘wni about I00 countries of .4I’riCil. ASiiI and Latin .4mcrica in pwjccts cavering priICtiCaI!y every sector of agriculture. fkxtry. ccunomic development. sociii! services and institutiona) and material infrastructure. ‘I‘hc Ci’I‘L is commissioned to do this work both hv the Govcrnmcnt of the !-cdcral Republic of’(krman~ ilnd by other government or semi-govcrnmcnt authorities. The GTZ activities encompass: ilp!7riIlS;ll, technical planning. control wlc! supervision 01 technic;\! cchqX’riIlic)n fxx$xts commissioned by the Government ~)f the Fcdcra! Republic or by other authoritit’s providing illl advisory service tu other agcncirs ilISt) working 011iicvclo!~mcnt proJccts the rccruirmcnt. sckctlc)n, hricting. ;lssignmcnt, administr;ltion of‘ cxpsrt pcrscwncl and their \Vcll\\rc any! tcchmcal hackstopping during their !wriod ol‘ wqnmcnt provision 01’matcria/s and equipment for projects. plunning work. srlcctinn, purchasing and shipment to the devclnping countries lTUni~gcXlt‘nt of ilII financial obligations to the partner-country. Dcu~schcs 7cntrum I’iir !‘llr\rl~Llu~~g~~~~hnologirrl
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Henrik Norsker

The Self-Reliant Pot.ter: Refractories and Kilns

A Publicution of Deutsches Zentrum fiir Entwickhmgstechnologien - GATE in: Deutsche Gesellschaft fiir Technische Zusammenarbeit (GTZ) GmbI-I

Friedr. Vieweg & Sohn

Braunschweig/Wiesbaden

The Author:

Henrik Norsker has been making pottery since 1970. He left his pottery workshop in Denm:.irk in 1976 to establisl; ;: pottery school in ~1village in Tanzania. Since then he has continued working in developing countries uith the promotion of modern pottery. Hesides Tanzania he has been involved in ceramic projects in Nepal, !ndia and Bangla.lesh. He is presently working on ;t pottery project in Burma.

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1SHV 3-528-02031-8

19x7

Lcngcrich

This book about how to construct and tire kilns addressestrainees and practising potters in developing countries. It intends to assist potters to become more self-reliant by providing advice on the optimum use of locally available raw materials and by explaining techniques which will help potters to increase their production and their income. The first section of the book describesthe whole sequenceof producing refractory items. The second section deals with different kiln types and their functioning principles. The various methods of constructing kilns are treated in a practical way with comprehensive illustrations. Finally instructions are provided L:? the loading and tiring of kilns and on different methods of measuring temperature, including a thorough description of how potters can make their own pyrometric cones.

L@llB Deutsches Zentrum fiir Entwicklungstechnologien

r' .-. _I'

Stichting

tool

ISBN 3-528-02031-8

Il.:I:

TOOL

/ Enlrepbtdok 6EW6%, ’ 1018 AD Amsterdam The Netherlands. 1 Tel (0)20-264409

Contents

Preface ...................................................... l.Refractories ................................................. 1.1 fntroduction. ............................................ I?.e Refractory raw materials. .................................... 1.2.1 Kaolin ........................................... 1.22 Fireclay ........................................ 12.3 Aluminous materials ................................. 1.2.4 Bauxite .......................................... 1.2.5 Laterite ........................................ 12.6 Silimanitc, kyanite. andalusitc .......................... 12.7 Zircon .......................................... 1.2.8 Silica ........................................... 1.7.9 ‘fow to get refractory materials ........................... 1.3 Production of refractory items ................................ 1.3.1 Clay cleaning ....................................... 1.3.2 Grog ............................................ 1.4 Kiln furniture ........................................... 1.4.1 Saggarsand slabs .................................... 1.4.2 Thermal shock ...................................... 1.4.3 Saggars.......................................... 1.4.4 Shaping ......................................... 1.4.5 Kiln shelves ...................................... and slabs .............................. 1.4.6 Drying of s:,_y+rrs ....................................... 1.4.7 Firing sJ!’ .................................. dlppOrt 1.4.8 Clai~ci ........................................ 1.5 Firebricks .lcks ...................................... 1.5.1 SO! ,, tirebricks .................................. 1 5.2 Ill\ x53......................................... 1.53 As i.5.4 I8 ijrebricks .................................... 1.5.5 hldlr.!ls ........................................... 1.6 Testing refractories ....................................... I .6.1 High temperature testing ............................... 1.6 : Refractory materials and bodies .......................... I .fi 3 Refractory items .................................... ................................................... 2.Kilns 21 L)evelopmentof kilns ...................................... 2.1.l Bonfire krlns .......................................

7 9 9 10 10 11 11 11 11 12 12 12 13 14 14 15 19 IQ 20 21 21 26 27 27 28 31 31 35 36 37 38 38 39 39 42 43 43 43 3

Sinde up-draught ki!n ................................. 2.1.3 Bangladeshup-draught kiln .............................. 2.1.4 Permanentup-draught kilns ............................. 2.1.5 European up-drauy’-f kilns .............................. 2.1.6 Down-d+++ t .IVS .................................. .................................... 2.1.7 Khurja kil 2.1.8 Mayangoneali ...................................... 2.1.9 Bujora down-draught .................................. 2.1.10 Cross-draughtkilns ................................... ................................... 2.1.11 Tubekilns ..... 2.1.12 Chinesechamber kiln ................................. 2. I .I 3 Champaknagarchamber kiln ............................. 2. i .14 Sumvecross-draughtkiln ............................... Choice of fuel ........................................... 2.2.1 Firewood ......................................... 2.2.2 Agricultural waste .................................. 2.2.3 Peat ............................................. 2.2.4 Lignite ........................................... 2.2.5 coal ............................................ 2.2.6 Oil products .................................... Combustion and fireboxes ................................... 2.3.1 Combustion ........................................ 2.3.2 Firewood tirebox .................................... 2.3.3 Sawdust firebox ..................................... 2.3.4 Coal fireboxes ...................................... 2.3.5 Oil drip firing. ...................................... 2.3.6 Pressureburner system ................................ Heat transfer and draught .................................... 2.4.1 Transfer of heat through air ............................. 2.4.2 Transfer of heat through solids ........................... 2.4.3 Transfer of heat by radiation ............................ ?.4.4 Natural draught .................................... 2.4.5 Flues ........................................... 2.4.6 High altitude ....................................... Kiln construction ......................................... 2.5.1 Site of the kiln ...................................... 2.5.2 Foundation ........................................ 2.5.3 Masonry .......................................... 2.5.4 Floor and wails ..................................... 2.5.5 Curved walls ....................................... 2.5.6 Arches ........................................... 2.5.7 Domes ........................................... 2.5.8 Catenary arch ...................................... 2.5.9 Arch construction without support ........................ 2.5.10 Expansionjoints ..................................... 2.5.11 Insulation ......................................... 2.1.2

2.2

2.3

2.4

2.5

4

46 46 47 48 50 51 53 53 55 57 58 58 42 63 64 67 68 68 69 70 71 71 73 76 78 82 85 88 88 88 88 89 91 91 91 91 91 93 94 95 95 99 102 102 104 104

2.5.12 Maintenance of kilns .................................. 2.6 Loading and setting of the kiln ................................ 2.6.1 Loading biscuit firing ................................. 2.6.2 Loading glaze firing. .................................. 2.7 Kilnfiting .............................................. 2.7.1 Biscuit firing ....................................... 2.7.2 Glaze firing ........................................ 2.8 Temperature measurement ................................... 2.8.1 Thermometers ....................................... 2.8.2 Colour ........................................... 2.8.3 Test draw ......................................... 2.8.4 Cones ............................................ 2.8.5 Pyrometer ......................................... 2.8.6 Self-madecones ..................................... Appendix .................................................... Tables of weights and measures.................................... Table of Segercones ........................................... Table of Orton cones. .......................................... Averageproperties and measures ................................... Mohs’ scaleof hardness. ......................................... Temperature conversion ......................................... Useful formulas. .............................................. : ................ Bibliography. ...............................

104 105 106 107 112 113 116 119 119 119 119 120 121 122 126 126 128 128 129 130 13 1 132 134

5

Preface

The idea of writing a ceramic book specifically to suit conditions in developing countries originated from my personal experience and associatedproblems whilst 1 was struggling to set up modem pottery production in a Tanzanianvillageten yearsago.When1was a potter in Denmark,ceramic raw materialsand kiln refractories had only been a question of which supplier to contact whereas iu Tanzania we had to find our own clay and glaze minerals, produce firebricks and kiln slabs, and construct the equipment locally. From that experience I realized the shortcomings of my former training and how difficult it was to extract appropriate technology from currently available ceramic literature. This literature mainly addressesitself to a market comprising amateurs, art potters and industrial engineersin developedcountries. Cenerally, the hobby books are too basic and the engineering books are too advanced to be useful to most potters. The art potters’ books provide a great deal of useful information. However, they do not cover all the fund: mental problems facing the potter in a deveioping country, e.g. how to produce refractories. The term self-reliant potter closely reflects the working conditions in which potters in many developingcountries have to exist. Imported materials and equipment are virtually impossible to obtain and even rhe supply of resources within the country may be impractical due to poor logistics or difficulties with local government bureaucracies. Selfreliance is therefore not seen as an end in itself but as a means to ensure a profitable pottery production.

The aim of this book is not to enable somebody without practical pottery experience to start up modem potttry production on his own. The book is mainly written for the benefit of potters already involved with modem pottery, and for teachers and students involved with the growing number of pottery training centres and institutes in developingcountries. GATE is planning to publish more technical books on ceramic technology and these would cover the subjects of glazing, clay preparation and shaping methods. GATE invites users of this book to forward their comments and any suggestions regarding the planned future seriesof ceramic books.

AC:-:?owledgments A number of friends, potters and colleagues in Denmark, Tanzania, India, Nepal, Bangladesh and ‘Burma have over the years participated in the process of establishing the raw materials for this book. I wish to thank them all for sharing with me the frustrations, disappointments and occasional triumphs of that process. Knud Erik Asak initiated me to the art of kiln building and he has contributed a number of photographs and the design of the Champaknagarkiln. Troels Kvoming has taught me the basics of pottery and has kindly let me use some of his photographs from Tanzania. The technical details of the kerosene pressure burner are provided by JamesDanisch 1

7

who has also contributed to the book with helpful suggestionsand photographs. Kaung Kaung 00 has helped with working drawing; for some of the kilns. Peter Nauman has produced the majority of the drawings and has had the tedious task of correcting my English and proof-reading the manuscript. The manuscript has been typed and retyped severaltimes by Nan Win Moe.

Finally I owe thanks to my wife Tin Tin Moe for her encouragement and patience with the writing of the book. My thank.; to all of you.

Rangoon, 27th December 1985 Henrik Norsker

ls Refractories

1.1 Introduction For the constructian of k&s it is necessary to use bricks and mortars which will endure intense heat. For glaze firings it is also usually necessaryto have materials for stacking pottery in the kiln chamber Saggars.kiln shelvesand props are examplesof kiln furniture. Industrial srandard

By industrial standardsa clay is called refractory when it does not soften below 1580 ‘C. However, in most caseswe will have to be satisfied with clays that soften at a much lower temperature because real refractory claj;. may not bc available or is too expensive. In any case,most potters will not bring their kiln above 1250 “C and will only maintain the maximum temperature for a short period.

Potter k refractory

For the purpose of this book the term refractory will cover clays and materials that are suitable to be used in a potter’s kiln fired up to 1250 ‘C. In casethe kiln is to be tired at a lower temperature, it might be possible to use ordinary building bricks and saggars made by less refined methods than those described below. However, the principles remain the same and the additional effort will often be rewarded by a longer life for the kiln and kiln furniture.

Fig. l-1: Tube kiln of Korean were the first to use refractory

type. The potters of the Far East clays for their kilns.

9

1.2 Refractory

raw materials

in most casesrefractory items for ordinary potteries will have to be made of clay.

siderable amount of sand which is left behind when the parent rock has changedinto clay. Sometimes only a small part of the parent rock is changed into clay ad in other cases raw kaolin occurs in pockets amongst granite rocks. The raw kaolin is normally

1.2.1 Kaolin a) Ancient

times

bl Ancient

times - weathering

Kaolin, also calied China clay, is the best refractory ciay type. A pure kaolin clay wiU not soften below 1750 “C. Kaolin has been created by the decomposition of feldspar (fig. l-2). Prirnqv

clav

Pure kaolin is found at the site of its parent rock (primary clay) and has not been mixed with impurities which would reduce its refractoriness and change its colour. Kaolin clays possess little plasticity due to their large clay particles. Porcelain

Pure white burning kaolin is much in demand for making porcelain and is therefore expensive. However. for the production of refractory items, kaolin firing to a buff colour is acceptable.

Often it is possible to find a local source of kaolin. It will nd,rmaUybe mixed with a conk’&. l-2: Espohed to the action of weather the feldspar rocli is slowly changed into clay. Chemicslly this change is written: N,I, KO? . Al203 . b SiO, Feldspar: 1 kaolir: Al203 . 2 SiO2 + Ghca wnd’ .L . 4 SiO2 + potash, so&u K + Na The pot:lsh and sod:1 are washed away and add to the salt in the oceans.

10

c) Today

white but some types of rock produce a pinkish colour which may still be a suitable.refractory clay. Solid firebricks can often be made from raw unwashed kaolin. Kaolin is also used in the production of paper and rubber.

Bauxite is the raw material from which the metal aluminium is produced. It is found in many places though only a few deposits are utilized. Even deposits which are not suitable for aluminlum production may be useful to the potter. Bauxite grog

1.2.2 Fireclay Fireclays are produced in the same way as kaolin but have been transported away from the location of the parent rock (secondary clay). Fireclays are also refractory, but often more plastic than kaolin. The colour of raw fireclays varies from white to yellow, brown or grey, and the sand content can be more than 50%. Sometimes the term fireclay is used only for the clays lying below and between coalseams. Such clays do not occur under all coal-seamsand they might not always be refractory. However, there is a good chance of finding a suitable fireclay where coal-seams are located. Evenunder inferior coals such as lignite it is sometimes possible to find suitable clays. 1.2.3 Aluminous materials

Generally the more alumina in a refractory body the better is its refractoriness. So if alumina-rich materials are availableat a reasonable price they should be added to the refractory body. The local institute of geology or mining should be approached about the availability of some of the following materials: 1.2.4 Bauxite

Al103 Hz0 melting point: 1600-1850 “C density: 2.9 g/ml hardness: l-3

Red bauxite is less refractory than white or grey bauxite. The bauxite has no plasticity and needs a binding clay. The raw bauxite should be ground, mixed with 25% plastic clay, shaped in rough bricks which are fired to about PO0‘C, and then crushed. This material can then be used as ordinary grog in a refractory body. A standard mixture is 75% bauxite grog and 25% fireclay. Bauxite grog can also be used as a substitute for a portion of the grog in the production of ordinary re&actor-y bodies. Calcination

The process described above of firing the rough bricks of bauxite is called c&nation. The raw bauxite cannot be used without calcination (calcination at 700-900 “C; above 1000 “C bauxite becomes hard to grind) because it shrinks a lot during firing, giving off about 25% in water.

1.2.5 Laterite

In the tropics laterite soils are widespread. It is a reddish clayey material which hardens when exposed to air. Most laterites contain too much iron oxide and other impurities to be of use for refractory purposes. However, some purer forms of laterite can be used. Late&es vary a great deal and their usefulness has to be tested by experimental use. Bauxite is rather similar to laterites but has a higher aluminium content. 11

1.2.6 Silimanite, kyanite, andalwite

AI: OS.Si02 Melting point: 1850 “C 3.2-3.6 g/ml Density: 6-7 Hardness: Silimanite is found mainly in India while andalusite and kyanlte are more widespread. Although these materials may cost too much for mos! potters, they are good refractory materials and produce long-lasting kiln shelvesand saggars.In India some smaller potteries have started to use silimanite for their saggarsand found this to be economical as it has extended the life of the saggais. The three materials are rather similar except that silimanite and andalusite can be used raw while kyanite needs to be calcinated above 1350 “C at which temperature it expands by 17%. (If intended for use below 1350 ‘C the calcination may be omitted.) The materials are non-plastic and can be used in mixtures as grog. A saggar body could be 60% silimanite, 30% fireclay and 10%plastic clay. 1.2.7 Zircon ZrSi04 Melting point: 2550 “C Density: 4.2-4.7 g/ml 7-8 Hardness: Zircon or zirconium silicate is commonly found as beach sand. As it is much heavier than normal sand, zircon has usually been separated from other sands by wave action. It is highly refractory and is useful in making special setters for tiles and plates..Bigger items such as saggarswould, with the addition of zircon, become too expensive and heavy. When zircon is used to make pressmoulded items, an addition of 10 % fireclay is necessary,whir* i+nmsto be hand-mou!ded .Y” ..w... or thrown on the wheel need 30-40% clay. Zircon is very suitable for painting kiln 12

shelvesand saggars.The kiln wash is made from either pure zircon mixed with water or with the addition of kaolin. The wash prevents glazed ware from sticking to the settings.

1.2.8 Silica

Si02 Melting point: 1710 “C Dens%-: 2.6 g/ml Hardness: 7 Silica is found as part of rocks and clays and it is so common that it makesup 60% of all materials in the crust of the earth. Occurrence As a free mineral, not combined in clays and

rocks, it occurs as quartz rock, silica sand, sandstone, Qint pebble and as semi-precious stonessuch as agate,opal and jasper. / Refractory

The addition of silica makes a clay mixture more refractory. However, items exposed to sudden temperature changesshould contain as little free silica as possible.Some forms of silica contract and expand suddenly at certain temperatures (fig. l-3) and this causes the cracking of items such askiln shelvesand saggars.Firebricks for the kiln structure will be less exposed to sudden temperature changesand may contain somesilica without giving problems. Cost

For use in refractory bodies, quartz rock would be too Lastly and shouki be reserved for glaze-making. Silica sand 1s often more readiIy available ant! ha the advantagt~that its particie size as found is suitable for immediate use. All sandscontain silica in the form

r

quartz

temperature “C Fig. l-3: Three forms of silica with different rates of expansion. The cr;~.&ls of crystoballite expand suddenly at 220 “C and the quartz crystals expand suddenly at 573 “C. \vhzf! silica has no crystal form as in silica glassor ash it expands evenly.

of small quartz crystals but B particular sand may contain many other minerals which may reduce its refractoriness. In general, the whiter the sand, the purer it is. White beach sand and the sand remaining from kaolin mining are the purest types of sand. 1.29 How to get refractmy materials Industries

Information rbout where to get materials may be ohtained from existing ceramic industries, glass factories or cement factories which ail need good refractory materials. Even if fuebricks are available they might prove too expensiveand in any case raw refractory clay will still be neededfor the pro., duction of kiln shelvesor saggars.

C.33ulogikalinstitutes

Other sources of information are geological institutes and mining corporations but sometimes they are not well informed and are only concerned with big commercial deposits of high grade. Do not give up if they tell you that there isno refractory clay evailable. Clay sufficiently refractory for use up to 1200-l 250 *C is quite common and there is a fair chance of finding some. Surveying

In the end, potters may have to look for refractory materials themselves.Before starting to dig holes everywhere, ask local farmers and traditional potters if they know about a white or grey-coloured clay. A white clay is often already in use for other pur13

Fig. II:

Clay mining

in Bangladesh

poses such as whitewashing houses. Also contact loca! well-sinkers who should have some knowledge of what soils are hidden below the surface. Apart from kaolin, fireclay and silica sand, width can usually be found locdly, the other refractory materials listed above normally have to be purchased from a supplier. 1.3 Production

of refractory

items

1.3.1 Clay cleaning Some refractory clays can be used as dug for the production of firebricks but usually. and especially for the production of slabs and saggars,the sand in the clay must be removed. Kaolin-type clays often contain more than 50% sand which should be removed at the site in order to saveits transport cost to the pottery. Some deposits contain as little as 15%~clay but it may still be feasible to wash out the clay. The removal of sand is done by adding water to the clay in a pond and stirring it until the clay is suspended in the water. The sand will settle first and the water clay mixture is transferred to another pond where the clay will settle more slowly. The stirring may be done mechanically or by hand: the principle is the same. 14

Fig. l-5: The day is stirred in the pond to the back. It is then poured through a screen into the small pit from where it runs to the fwo lower settling ponds.

Washitrgponds

For the clay cleaning, two or more shallow ponds (for example 4 x 2 metres and 1/2metre deep) should be dug in the ground close to the clay source. The sidesof the pond can be made of brichwork but simple wickerwork plastered with clay will do. The pond is half-filled with water and clay is added until the pond is filled. The , rw clay is stirred with a shovel until a!1the clay particles are separated from the coarser sand. With coarser types of clays, like kaolin. the stirring may not take more than 30 minutes but wit11finer clay a longer period is needed and it may be necessaryto let the mixture soak for a day. When no more lumps are left and the feel of the material at the bottom of the pond is no longer clayey but sandy, the clay slip mixture is transferred to the second pond. The slip can run by itself if the second pond is placed lower or it can be transferred with a bucket. In the latter case the slip could be poured through a screen into a small pit connected to the second pond. In the second pond the clay is left to settle. The rate of settling depends on the fineness of the clay. For highly plastic clays it may take weeks but for kaolin clays it will often take less than a day. After the clay has sett-

which is fusibie compared to mo;e refractory silica s?Ad.) From time to time the tray should be turned upside down for cleaning and occasionally the washmii wil! have to be emptied of sand. 1.3.2 Grog

Fig. l-b: After setthnp dried in the sun.

the washed

kaolin

clay

is

led the clear water on top should be run off cautiously without stirring the settled clay. The water can be reused by transferring it to the first pond by the help of a pump or by bucketing. The bucket or the pump inlet should not be dipped into the settling pond becausethat would stir the clay. Instead the surplus water should be conveyed to a small third pond from where it can be returned to the first pond. If there is a sma!l stream nearby. the waste material can be used for making a small dam to provide water for the claywashing. Washmill

For large cluantities of clay an animal-powered washmill can be used (fig. l-7). This can be operated continuously and raw clay can be added while the stirring is taking place. This addition will force clay slip to I-unoff at the top. The raw clay will sink to the bottom where the action of the stirring blades will disintegrate it. The clay will become suspended in the water whi!e the coarsermaterials remain at the bottom. The clay slip is then led into settling ponds through a screen. If a very pure clay is needed, the clay slip can be led through a grooved tray (fig. 1-7) where the grooves will retain the very fine sand. (This fine sand is likely to be mica

Grog is burned clay which has been crushed to grains of various sizes. It is used for making solid firebricks, saggarsand slabs,etc. The grog is mixed with a plastic clay which binds it together. The additiona! firing and crushing make it more costly to use grog instead of raw clay but the benefits soon become obvious. These are: 1. The firebricks or saggarsare much lesslikely to crack with sudden changesof lemperature. 2. They will better withstand loads without bending. 3. The tendency of spalling’ is greatly reduced. 4. The drying shrinkage is reduced as less water is used in the clay and grog mixture. 5. Firing shrinkage is reduced because the grog has already been fired once. Generally the !ligher the con tent of grog the better the refractory properties, but Phaping,especially of saggars,demandsa certain plasticity. Grog production

Grog is produced by firing lumps of raw clay in the kiln, or the raw clay can be formed into rough bricks, which are easier to set in the kiln. The clay used for making grog should be more refractory than the bond clay which binds the grog grains together. The grog clay should contain as little sand (free silica) as possible. A grog clay lacking -- ----’

‘The cracking of a tirebrick change is called spalling.

due to temperature

15

Fig. l-7: Animal-powered

w~shmill

for clay cleaning.

plasticity will be difficult to form into rough bricks and will be troublesome to stack in the kiln. An addition of about 10% plastic clay will solve the problem. If possible the grog clay should be fired at a temperature which is higher than the temperature the 16

A grooved

tray leads to the settling

tanks.

finished refractory items are likely to be used at later. However, this can be difficult for small potteries which cannot afford to build special kilns for grog and firebrick production. Alternatively, the grog bricks can be placed at the hottest spots in the kiln.

Fig. l-8: A manual hammer

for grog crushing

Hroken saggers

When the pottery has been in production for some time broken saggarsor kiln slabs and old firebricks should suffice for the grog production. However, care should be taken to remove any layer of ash slag or melted ghue as these materials will lower the melting point of the finished product.

After firing, the grog is initially reduced by a hiinlmer to lu~nps the size of about 5 cm. For the final crushing the hammer pictured in fig. l-8 should be adequate for most smaller potteries. The hammer IS operated by stepping on the shorter end of the lever and then left to fall by its own weight onto

Fig. 1-9: A pan grinder supplied with a doubledeck screen grades the crushed grog in two sizes.

the grog which is placed under the metal or stone hammer by a second person. For bigger potteries a jaw roller, impact crushers or pan grinder (fig. l-9) may prove more useful for crushing large amounts of grog. A hammer mill (fig. l-1 0) designedfor milling corn can be used by changing the screen and reinforcing the cageto withstand the abrasive action of the grog. Grog particles should be angular and plate-like rather than rounded. For these shapes a hammer mill is more suitable compared with the other machines. Grog size

The size of grog should normally be between 1 mm and 5 mm. In general, fine grog mixtures tend to withstand loads better but are 17

Fig. l-10: the crntre

The inside of ;i hammer mill. The hammers swing out when they rotate. hole to the right and Iewes through a screen (removed) on the left.

more prone to cracking after repeated heatings. Therefore smaller items can be made with a higher proportion of fine grog while bigger items should contain a greater amount of coarse grog. Otherelriseequal amounts of fine and coarsegrog should be used. DlN

In any case the grog should have the dust fraction removed. Dust will reduce the 18

‘The grog is fed through

plasticity, lower the melting point and it contains much free silica. The dust is best removed by washing. Alumimus grog

Andalusite. silimanite. kyanite, bauxite and laterite minerals mentioned earlier can be substitutes for clay grog in the refractory mixtures described below. In clay mixtures these materials act in the sameway as grog.

1.4 Kiln furniture

1.4.1 Saggarsand slabs

Saggarsare used for protecting the glazed ware against the action of flue gases and ashesfrom combustion of solid fuels, which otherwise might cause discolouration *md give the glaze a rough surface where ayh has settled on the ware. At higher firing temperatures firewood ash melts together with the Fig. 1-l

I : Saggus stacked

3 m high

glaze and if the co!txr effect of the ash is acceptable an open setting with kiln shelves, also called slabs, is preferable. Saggan are heavier and take up more spacecornpart d to the samewei@ ot kiln shelves.However, if the height c:f the setting is more thdn two metres a setting with kiln shelves t,:nds to become t;Jo unstable whiie sagparscan be stacked to above four metres. The sameclay mixture can be used for both saggarsand slabs though clay mixtures ibr kiln shelves need lessplasticity. Fig. 1-l 2: Open setting with wood to 1280 “C

on kiln slabs in ;1 kiln fired

Grog content

As a rule of thumb the mixture should contain as much grog as the shaping technique allows. Normlly

that is 40-60% but it de-

pends on the plasticity of the bond clay. It is unusual to find a clay being both highly plastic ann refractory, and so usually the bond clay is made from a mixture of a stoneware clay or a vitrifiable plastic clay and a refractory clay such as kaolin. The bond clay shouid start to vitrify at a low temperature but should not soften before well above the firing temperature. The kaolin crystals in the clay start slowly to change into mullite crystals (fig. l-13) above 1000 “C. Mullite grows irlto long needle-shapedcrystals which form a lattice that will reinforce the fired clay in much the same way as iron bars in reinforced concrete. This lattice-work enables the kiln furniture to carry the load of the w3re at high temperatures. The partly melted mass between the grog particles will enable the mullite crystals to grow freely. If the bond clay was too refractory the needle crystals could not grow properly and the slabs would bend. This can be seen from the fact that newly fired slabs tend to bend. However, after they are fired a few times Fig. 1-13: Lattice-work of mullite crystals reinforces the fired clay. Kaolin crystals change gradually into mullite at high temperatures. The crystals are shown 100 000 times bigger than they really are.

and the lattice-work is allowed time to grow they no longer bend. As the right proportion of grog and bond clay dependson the quality of raw materials, firing temperature and shaping technique, the local potters will have to find their own recipe by trying a number of different mixtures. R ecives

The following recipes are practical examples of saggarbodies: (parts in weight) recipes b saggarclay 3: 25 3; kaolin 15 15 30 55 60 30 grog: Bodies for making slabs ciLrrbe made with a higher content of grog compared to bodies for saggarproduction. 1.4.2 Thermal shock

In mcst casesthe potter will be more troubled with cracking of saggarsor slabs than with fusion and softening of the ki!n fumiture. Due to their shape, saggsrs tend to crack more easily than slabsbut the problem is often caused by the same problem, thermal shock. Expansion

All materials expand when heated. Kiln furniture, ware and the kiln lining itself expand about 1% when heated to 1250 “C and will shrink again as the kiln cools. If the heating and cooling processis slow and even, all items in the kiln will expand or shrink at the same rate. However, if a saggar for example is heated or cooied from one side only, the two different sides of’ the saggar will expand at different rates. That will cause tension and the saggarcould crack. Especially around 573 “C and 230 “C the heat-

ing and cooling should be done slowly (see p. 115 f.). The following can be done to reduce the problem of crxking: 1. Reduce the amount of sand(free silica) in the clay. Sand is not the only source of free silica. Clay produces free silica when heated above 1000 “C. Kaolin-type clay releases about 36% whereas other clays as montmorillonites (bentonite) release up to 60 5%. Thus a changeof bond clay should be cordered too. 2. Increase the amount of grog to make the fired body more porous. A porous body W8 more easily accommodate tensions than a dense body. Porosity of saggarsshould be 18-25% (seep. 42j. 3. If the firing temperature is below 1250 “C an addition of 5-12% talc will improve resistance to thermal shock. Tdc will reduce the melting point and lherefore can be used Only at lower temperatures. Talc is used for making corderite bodies Hrhichhave a high resistance to thermal shock. The formation of corderite is difficult to achieve. 4. Biscuit-fire the kiln furniture. 5. Changethe firing and cooling scheduie t6 ensureslow changeof temperature at 230 “C and 573 “C. One pottery found that saggars lasted 6-l 1 fir@, when cooling of the kiln took 24-72 hours. The samesaggarslasted 50 or more times when the cooling took 168 hours (Searle,“Refractories” p. 575). 1.4.3 Saggm

hparation

of saggarbody

The different clays and grog are measured out according to the recipe. That can be done either by weight or by volume, whichever is more convenient. But take care to follow the samemethod each time so that the composition of the body doesnot vary. The grog should be wet before mixing with the clay. The clay and grog are spread out in

Fig, l-14: Verticalpugmill for claymixing, A similx ptlgmill canbe poweredby an ox. alternate layers on top of each other. Each layer is watered as required. After one day the clay is soaked and the mixture is turned upside down with a hoe or spade or pugged in a pug mill. If necessarymore water is added. It is then left to mature for two or more days while covered with plastic sheets or wet bags. Before shaping, the mixture is thoroughly kneaded either manually or in a pug mill. 1.4.4 Shaping Saggarshapes

The shape of the saggarsshould suit the size of ware and kiln to enable the packing to be as denseas possible.The shapeis determined 21

Fie. I-l 5: Different

shape.\ 111’sagprs

by the formi:lg method, i.e. throwing and jolleying will produce only round saggurs whereas with hand-moulding and sLp-casting more shapesare possitle. Also, separate sides and bottoms will reduce the stress on the saggars due to thermal shock, but it demandsaccurate shaping. Saggarscan be made by five different methods: a) thrown on a wheel, 0) jigger-jolleying, c) hand-moulding, d) press-moulding and e) slip-casting. a) Throwing

Saggarsup to about 30 cm in diameter can be made by throwing on a wheel. The clay is placed on the wheel and beaten into a flat round shape of the required diameter. The inside of the saggaris then formed by beating the clay until the bottom has the right thickness (1.5-2 cm). The excess clay is now at the outer rim. A thick slurry of the sameclay body is added and the clay at the rim is drawn up to form the wall of thz saggar. The thickness of the wall should be even and the shape of the saggarcylindrical. The bottom is levelled and the diameter and height of the wall are checked with a ruler. The surface of the saggaris made smooth with a steel blade.

Fig.

l-16:

Saggers

shaped

for

dense

setting

of

hO\Vl\

Saggarshigher than about 10 cm cannot be thrown in one operation. After the saggar has stiffened more clay is coiled on top and the wall extended by further throwing.

Fig. I-17: mould and

Jalley machine with rotatlq! template in this case for m;lking

pbstcr plates

high porosity. The saggar cla) should be softer than clay for throwing. The mould should be slightly wet before throwing the required amount of clay into it. The clay is pressedinto shapeby lowering the template. For bigger saggarsit is necessaryto pressthe clay out evenly inside the mould by hand before lowering .the template. Excess clay is cut off at the rim and the mould is lifted off to be replaced by another. Depending on the clay and the weather each mould can be used 2-4 times a day. c) Haa,td-moulding

li) Jigger-jollcying

A saggarby this method is normally formed inside a rotating mould (jolleying) by the pressingof a template. This method is especially suitable for shaping of smaller saggars up to 20 cm in diameter. The saggarscan be made into shapes which allow a dense setting. A normal potter’s wheel can easily be equipped to work as a jigger-jolleying machine. The moulds are usually made of plaster of Paris but can also be made of clay burned below 900 “C to give the moulds Fig. I-18: Plaster moulds formed by jollcying

filled

with drying

saggar\

The saggarclay for hand-moulding should be stiff. An iron ring or frame slightly bigger than the bottom of the saggaris placed on a board. The board is dusted with fine grog and saggarclay is thrown into the frame and beaten out until it fills the frame. Excess clay is cut off by a wire and the frame is removed. The sides of the saggarare moulded

Fig. l-1 9: \vooden

mould

for saaar-making

joining

slab and base Fig. the out. and

t removing

mould

I

Fig. I-20:

Hand-moulding

1-21: A saggar-moulding shop. On the table to right the skbs of bottom and sides are beaten On the revolving table to the left the bottom sides are joined and made smooth.

While the drum is still inside, the outer surface is made smooth with a steel blade or sponge. After removing the drum the inside is also made smooth, The saggar is left to stiffen a bit and is then turned over so that its bottom can be levelled and made smooth.

of a saggar

d) Press-moulding

into a long slab of clay paste between two strips of wood fmed to a board. As before, the board is dusted and the clay is then beaten well and excessclay is cut off. This slab is then wrapped around a wooden mould or drum forming the inner shape of the saggar. The slab of clay paste can be moulded on top of a long piece of cloth which will support the clay while wrapping it around the drum. The ends of the strip are cut and kneaded together. The drum and the clay are then placed on the previously prepared bottom which has been smeared at the joint with a clay slip. The sides and bottom are then kneaded together and excessclay at the bottom is cut off. This operation is best done on a revolving table. 24

Slabs and saggarscan be pressed in a steel mould. Pressure is applied by a fly-wheel screw presswhich can be operated manually. Such pressesare not very expensive(in India a manual saggar press in 1985 cost about $ 1000) and produce saggarsof a quality superior to hand-moulded saggars (although some saggar-makers claim that properly hand-made sae;a;ars are superior). The mould is greased with oil to ensure the proper release of the saggar.The quality is considerably improved by applying two or three extra tugs of the press. The mould should be slightly conical to enable releaseof the up per mould and the saggar,without distorting the clay sides. After a long period of use the mould may need machining to ensure a smooth conical surface.

Fig. l-22: Slabs, saggars and moulded in iI fly-wheel press.

firebricks

can be

e) Slip-casting

Slip-casting is done by pouring a clay slip into plaster of Parismoulds. The moulds will Fig. 1-24: Plaster mould

for solid slip-castings

of saggars

Fig. 1-23: Release of ~ggar powered fly-wheel press

from

an electricaly-

absorb the water in the clay slip and the clay will harden. After some time the clay shape can be taken out. Saggarsare normally cast in solid cast moulds (fig. l-24).

Slip-casting has the advantagethat the shaping does not require plastic clay and so the mixture can contain a much higher proportion of grog compared to the other methods. Although the ceramic industry uses this method extensively, smaller potteries may experience difficulties due to the cost and availability of plaster. Furthermore, chemicals such as water glassor sodaare neededfor making the clay slip fluid with a water content equal to plastic clay (20-30%). Without these chemicals the water content Leeds to be 40-50%. 1.4.5 Kiln shelves For an open setting, square flat kiln shelves, also called bats or slabs, :re used. These are normally made by hand-moulding although they can also be press-moulded and slipeaL.i. Gay mixtures and clay preparation for hand-moulding are similar to those of saggar-making though a higher content of grog is permissible and the clay paste should contain lesswater (semi-dry). Fig. 1-X:

Kiln slabs used in a shuttlc

Forming

An iron or wor&n frame having the shape and thickness of the finished bats is placed on a s&d bench or on a concrete floor and is sprirtied with grog dust. The semi-dry cl?y paste is gradually added by starting at one end of the frame while beating the clay constantly with a wooden hammer. The stroke of the hammer should always have the same direction, opposite the direction of filling the frame. After ftiing the frame completely the surface is levelled by running a wooden stick on top of the frame. The surface is made smooth by a spongeand a steel blade used alternately. A plate fitting exactly inside the frame is placed on top of the slab while the frame is lifted off. The four sides of the clay slab are carefully made smooth and the slab is left to stiffen for about a day. It is then turned over .andits bottom is made smooth.

kiln

Fig. l-26: Separable wooden frame for slabmaking. The sticks have the thickness of the slab.

Thickness

The thickness and size of slabs depend on the quality of the raw materials and on the firing temperature. The higher the temperature, the thicker the slabs need to be to carry their load without bending. A slab measuring 30 x 30 cm should before drying have a thickness of 3-4 cm. 26

Fig. I-27: Beginning at one end semi-dry - clay- is _ arladuaily compacts the &y with even strokes in one direction.

Firing of slabs

The slabs have to be fired once before being used. For the first firing the slabs should be fired while standing on their edge although at high temperatures they tend to warp if not supported from both sides.Alternatively they could be fired to about 1000 “C the first time. Normally slabs will bend during the first couple of firings. The remedy is to place the bent slabs with the bend upwards at the next firing. After a few firings the slabs will stop bending because reinforcing mullite crystals have formed (seep. 20). 1.4.6 Drying of saggarsand slabs

Saggarsand slabs should be carefully dried to avoid warping and cracking. Big saggars are particularly sensitive to stresscaused by uneven drying. After stiffening sufficiently the saggarsand slabs could be stacked two by two or more in order to slow the drying and reduce any tendency to warp. During dry seasonsthe items should be covered with plastic sheets.Saggarsand slabs will crack if

filled

into the frame

while

a wooden

hammer

the outer part sticks to the board or floor on which they rest but this can be prevented by dusting with grog or setting the saggarson paper. 1.4.7 Firing saggars Saggarswill last longer if they are fired empty the first time and to a higher temperature than they will be working under later. Often potters will fire their green saggarson the upper layers in the kiln and they will be tempted to ful them with glazed ware too. The individual potter must try out both ways and decide‘ for himself which is the more economical. Saggarlife

The potter should always record how many fresh saggarsor slabs he fires at each firing so that he can control if the breakageof saggars or slabsbecomestoo high. Large saggars made from clay seldom last more than 4-6 firings up to 1250 “C. Provided a goodquality fireclay or kaolin is available for saggar27

making and the fling and cooling of the kiln is done carefully, a saggarlife of lo-20 firings may be possible. Slabs will normally withstand many more fnings than saggars.

Clay body

Supports such as spurs, thimbles and stilts are made by press-moulding. The body for this should be made from a fine-grained fireclay or by mixing kaolin, silica sand and plastic clay in the following proportions:

I .4.8 Glazed ware support

Various types of supports for the setting of glazed ware make it possible to place the pots more tightly in the kiln, thereby improving the firing economy. In the chapter *‘Loading and setting of the kiln” page 105 ff., a number of different supports are described.

kaolin plastic clay silica sand (by weight)

60 15 25

The clay body should be screened with a fine mesh sieve(80-100 mesh, seep. 127).

Press-moulding

The clay body should be press-mouldedin a semi-dry state with a water content of lo15 5%.The higher the pressure applied in the mould the less water is needed. The mould could be made of mild steel or brassif a lever press as shown in fig. l-28 is used. The mould should be made with a simple ejection device, which will push the finished item out of the mould. The mould should be greased with oil before each ftiing in order to ease the release of the press-moulded item. Alternatively oil could be mixed with the clay body. The mould could also be made of plaster or clay, but then less pressure should be applied. Crank

Fig. l-29:

Thimble

press mould

Fig. I-30:

Tile setters for stacking

Thimbles can be used for stacking flatware such as plates and tiles on top of each other

with ejector glazed roofing

tiles

Fig. l-32: and bowls

Fig. l-31 : Flat plates stacked

’

tightly

of pan rings for stacking

plates

in a crank

as shown in fig. l-31 provided that the flatware is made exactly samesize. A bottom and top plate each with three frxed sockets for the thimble pillars hold these together and the top plate also protects the ware from kiln dust. This kind of arrangement is called a crank and may hold 10-l 5 pieces. The top and bottom plates are made in a flat mould and formed in the sameway as kiln slabs. A template should be made for measuring the exact position of the three thimble sockets, which are carved out afterwards. Pan rings

Pan rings are used for stacking glazed plates and bowls on top of each other (fig. l-32). The pots may rest on the pan rings with their rims upside down or they may hang on the pan rings resting on their rims (fig. l-33). Pan rings are made from clay bodies similar to those prescribed for kiln slabs or saggars. The pan rings can be stock-moulded in the sameway as solid firebricks (p. 33), but ex30

Setting

Fig. l-33: Two on pan rings

different

ways’of

setting

the ware

tra care is needed to ensure that the step of the pan ring is filled completely with clay and that the step does not break off when the pan ring is released from the mould’ . The curve of pan ring is made with a radius that fits the size of plates or bowls to be stacked. Another method of forming pan rings is to place a thick coil of clay on a bat. The coil is laid as a ring with the desired diameter. This ring is then centred on the wheel and a template cut to the profile of the pan ring is used for shaping the ring. The ring is then cut into 8 or 12 piecesand left to dry’. The pan rings are fired and given the same kiln wash as other kiln~furniture.

t 2

This neer This son,

method is suggested by M. Cardew, “PioPottery”, p. 162. method is used and described by J.G. Jud“Studio Potter Book”, p. 272.

1.5 Firebricks Firebricks are used for the construction of a potter’s kiln and are also used in many other industries such as glassworks, foundries and boilers. If the potters can successfully produce firebricks for their own kilns they may be able to earn extra income by selling firebricks to these other industries. Industry today uses a number of different types of firebricks according to specialized requirements, but this book will deal mainly with solid and insulating firebricks made from clay. Solid firebricks are used for the fireboxes, chimney, bagwalls, floor and flue systems, while the kiln lining may be made of insulating firebricks. Fig. l-34: Construction fired in il pit firing.

of a test kiln in Bhnktapur,

15.1 Solid firebricks

Production of firebricks is less critical w!len compared to saggarsbecause firebricks are not exposed to as sudden temperature changes and rough handling. Furthermore, the shaping of firebricks demandslessplasticity from the clay. Some fireclays and kaolin clays can be used as dug. which is an economical method to produce solid firebricks, but grog may be a worthwhile addition to improve their refractory quality. The proportion of clay to grog will vary according to the plasticity of the clay and the conditions to which the firebricks will be exposed.

Nepal. The insulating;

firebricks

for the inner lining were

Two grades

The addition of grog increasesthe production cost and it may be preferable to pro. duce two grades. For example, firebricks for fireboxes, grates and bagwalls can be made with the highest possible content of grog (60-80%) while the rest of the kiln can be made with less grog (ZO-40%). The same grading could also be used for the bond clay so that first-grade bond clay, which has had its sand fraction removed, will allow for a higher content of grog. Bond clay The clay binding the grog together should be less refractory than the grog. Otherwise the brick will becomebrittle after firing. But the bond clay should not vitrify excessively or fuse because if the firebrick becomes too dense it will tend to spa11after long use though a high grog content will counterbalance this tendency. Often the best solution is mixing two different clays, e.g. a fusible stoneware clay with a fireclay or kaolin clay. The proportion will depend on the quality of the clays and the intended firing temperature. 8 solid firebrick recipes

Fireclay Fireclay grog Stonewareclay Kaolin Kaolin grog (measuredby weight)

a 80 20 f 10 30 60

b 60 40 g 10 40

c

d

e

SO 40 30 50 60 70

h 20 40 50 40

The mixing and preparation of the clay and grog should be carried out as described for saggar bodies. However, the moulding of bricks demands much less plasticity and so the water content can be lower.

Fig. l-35:

Slop-moulding

of bricks

Slop-moulding

Slop-moulding is done with a very soft clay paste. The mould frame is first dipped in water and then placed on a ground which has been levelled and dusted. The soft clay is forcefully filled into the mould and the top is levelled off by using a stick. The mould is then lifted and the brick is left t.o dry on the Fig. l-36:

Slop-mouldinp

frame

Fig. l-37: ing

ilpen

stacking

of firebricks

for even dry-

ground. At first the bricks will be too soft to handle but after a day or so they will be strong enough to stack for further drying. They should be stacked as shown in fig. l-37 so that air can dry the bricks from all sides. The slop-moulding technique is very fast but the bricks will have irregular shapes. It is mainly used for common red bricks, which are also neededfor the kiln construction. Stock-moulding

Higher density, more accurate shapes and greater firing strength are achievedby stockmoulding. A stiff clay paste is used in this method. The mould has two pieces;the bottom of the mould, which is called a stock, is fixed to a solid table and the top piece, called a frame, fits loosely onto it (fig. l-38). The inside of the brick mould should measure the size of the finished brick plus the total drying and firing shrinkage which can be determined from the testing of the firebrick mixture (p. 40 f.). The moulder should first

Fig. I-38:

Stock mould

fixed

to a solid table

Fig. l-39: Separable frame for moulding with semidry clay mixtures. The clay is pounded repeatedly while beingtilled into the mould.

prepare a lump of clay by bumping it several times on the table, giving it a square form which is slightly bigger than the inside of the mould. From above the head the clay should be thrown with full force into the well dusted mould. The clay should fill all comers of the mouid and is then ievelled off at the top with a stick. The mould is then lifted, with the brick inside, and an assistant can carry the mould to the drying ground where it is emptied by gently knocking the mould. Normally the bricks can be placed on their edge immediately. For firebricks, dusting is done with fine grog and not sand. Special shapes

Wedge and arch bricks are moulded iike square bricks but in specially made frames. Small numbers of special shapes, such as Fig. 14 1: Stacking bricks for firing in B clamp kiln. of clay and firing takes place in the two fireboxes.

Fig. I-40: Cutting of two templates

of special shapes with

the help

bricks for skewbacks or rounded bricks for flue channels, can be made by cutting freshly moulded square bricks. The square brick is placed between two templates of wood which have the desired profile, and a wire is When al1 bricks are set the kiln is sealed with a plaster

then drawn along the templates, cutting the brick (fig. 140). Firing solid firebricks

The problem in firing solid firebricks is that they should be fired at a higher temperature than the one at which they will be used later. (The same applies for insulating firebricks and kiln furniture.) If the pottery is already one that is in production then the bricks should be fired next to the bagwalls or in other hot spots in the kiln. In caseno kiIn is at hand, the bricks will need to be fired in a clamp kiln where the firing temperature will seldom exceed 900 ‘C. Kilns made of these low-fired bricks will tend to crack more than usual. This is caused by the extra shrinkage of the firebricks when they, as part of the brickwork in the new kiln, are exposed to a much higher temperature.

1S.2 Insulsting firebricks Insulating firebricks are made of a mixture of fireclay and sawdust. Other combustible materials such as coal, lignite, peat, rice husks, etc. can also be used as fillers and should be prepared like sawdust. The sawdust will burn away in the kiln and leave plenty of holes in the bricks. These holes make the bricks better heat insulators when they become part of a kiln becauseheat cannot pass through motionless air which is trapped in the holes. The insulating flrebricks have severaladvantagesover ordinary firebricks. Theseare: 1, Lessheat escapesthrough the kiln walls. 2. Less fuel is needed to heat an insulating inner wall becauseit is lessdense. 3. The surface of an insulating inner wall is hotter during firing and the increasedglow increases the radiance of heat to the ware (P. 88).

Fig. 142: Heat going through a sawdust insulating brick is stopped by all the pockets of air left by the burned out sawdust particles.

Fig. l-43: If the insulating holes are too big the uir inside the holes can rotate and thereby heut is transferred through the brick.

4. They are cheaper to make by using less clay and needing no grog. For thesereasonsinsulating firebricks should be used as much as possible. However, due to their open structure they are sensitive to slag attack and cannot be used in salt glazing kilns. Insulating bricks will collapse at a lower temperature compared to grog firebricks made from the sameclay. Smvdust

The sawdust should be screened through a mesh of at least mosquito net size. (This is 16 mesh but 24-30 mesh is preferable.) If the particles are too big the resultant holes in the finished brick will allow the &ir inside to rotate, which means the air will transfer heat (fig. 143). On the other hand, dust-size particles should be avoided. Hardwood saw‘dust results in smaller pores than sawdust from softwood, but hardwood sawdust is not always available. 35 .

Bond clay

For a bond clay, the clay should be as refractory as possible especially if the bricks are for the inner lining. For a back-up insulation behind an inner lining inferior clay may be used. The clay should have good binding power so that it can take a lot of sawdust. The binding power of the clay can be improved by the removal of its sand by washing. A washed kaolin clay with the addition of lo-20% plastic clay often produces very good bricks.

Fig. l-44: Sawdust bricks space apart during firing.

are placed

a finger’s

Firing Sawdust/clay mixtwes

The more refractoriness and binding power the bond clay possesses,the more sawdust can be added to it. The potter will have to test a number of different mixtures and perhaps even different bond clays. Measuredby volume the sawdust content will be about 40--60% with the remaining part bond clay. After adding water to the sawdust and clay, It should be mixed very thoroughly. The mixture is left a few days before moulding.

The bricks should be stacked in the kiln as shown in fig. 144. The burning out of the sawdust will raise the temperature rapidly and it will be necessaryto stop adding fuel while the sawdust bums. Otherwise, the rapid increaseof temperature will causedistortions in the bricks. The firing is easier to control if the sawdust bricks are fired in smaller quantities along with other ware. 1S.3 Ash bricks Silica in ash

Mouiding

Stock-moulding will produce more accurate shapes,but the sawdust tends to make the insulating bricks stick to the mould. The softer clay mixture used for slop-moulding is more easily released and the additional amount of water will also increasethe porosity of the finished brick. The choice of moulding method could be made after letting the moulder try out both methods. Sawdust bricks take a iong time to dry due to the great amount of water taken up by the sawdust. But the bricks will seldom crack during drying becausethe sawdust reinforces the clay body and givesthe clay a very open structure. 36

Ash can be mixed with a bond clay to make insulating bricks for use with temperatures up to around 1100 “C. The refractory value of the finished bricks very much dependson the type of ash which is used. Ash of rice husks contains more than 90% silica and high silica contents are also found in ashesof rice strdw and thatching grass’ . Ash resting

Some asheshave high contents of minerals which :ower the melting point. These are hf. Cardew.

Pioneer

Pottery.

p. 42.

usell in glazesbut not in firebricks. It is necessary therefore to make practical tests with the ash in question before using it. A mixture of four parts ash to one part clay (by volume) is a good starting point. Ash washing

Ashes high in potash and soda should have these soluble minerals removed by washing so that they are less caustic to work with. The removal of soda and potash will also raise the melting point of the ash. The washing can be done by leaving the ash in a pit outside during the rain.

IS.4 EIolIow firebricks

‘4

Fig. 1-45 shows press-moulded firebricks with two hollow rooms. These rooms are filled with rice-husk ash during construction. The kiln seen in the picture is constructed from these bricks and is fired to 1250 “C. Due to the low thermal mass of the kiln lining, the kiln is very fuel-efficient. It has been developed by the Central Glass& Ceramic ResearchInstitute of India with the aim of improving fuel economy of the round down-draught kilns at Khuja (p. 5 1).

Amorphous silica The silica in ashhas no crystal forms like the silica found in sand and quartz rocks, and because of this it is called amorphous. The importance of this lack of crystals is that amorphous silica does not shrink or expand suddenly as does the silica with crystal form (seep. 12). If ash bricks were made using a similar amount of silica but in the form of sand (crystal form), these bricks would be very prone to spalling or cracking due to sudden changesin temperature (thermal shock). The ash bricks using amorphous silica are much less likely to suffer these effects. The disadvantage with ash bricks is that the amorphous silica is much less refractory, and hence they are unsuitable for very high temperatures. Low duty

Ash bricks may be used in low temperature kilns and as back-up insulation in high temperature kilns but in either case thorough testing is necessarybefore relying on a particular ash and clay mixture.

Fig. 145: The hollow spaces of these firebricks are filled with rice husk ash. A prototype of a Low thermal mass kiln developed at the Khurja Centre is seen behind the bricks.

1S-5 Mortars

(a)

Mortars are used for joining firebricks in the kiln structure. They are also used for protective coatings of brickwork such as.the lining of fireboxes. The mortars should resemble the bricks they join so that the joints and the bricks expand and shrink at the same rate during a firing cycle. To enable an easy laying of the bricks the mortar should be plastic.

(b)

Grog Fine refractory grog (passing at least 24 mesh) should be used for reducing shrinkage in the joints. If the joints shrink too much they will fall out after only a few firings. Sand can also be used instead of grog, but too much sand will cause spalling of the joints. The amount of grog or sand depends on the bond clay, which may already contain sand. Usually grog makesup 50-65% of the mortar.

w’ (6)’

fireclay grog 40 mesh kaolin stoneware clay grog 24 mesh sand WI3 stoneware clay grog (or sand) fneclay

40 60 25 _ 8 67 40 40 20 1 2

The mortar should be applied as thinly as possible. In caselarge gaps need to be filled by mortar it is better to add a lot of coarse fm?. Outer walls

The outer walls are laid with common red bricks and a mortar made of a normal clayey soil can be used for the outside. Where the walls will be exposed to rain, the joints should be pointed with a sand/lime mortar in the proportion of five parts sand to two parts lime.

Bond clay

1.6 Testing refractories The bond clay could be the same as that used for making the bricks. The bond clay should be refractory, but it is better if the mortar is slightly fusible so that the joints will form a strong bond between the bricks. This can be achieved by adding a fusible plastic clay to the refractory bond clay. The exact amount of fusible clay depends on the firing temperature and if possible a few tests should be done. Normally 20-X% of the bond clay could be fusible clay, and the remaining part be similar to the refractory clay of the bricks.

Bagwalls, flue linings or saggarsthat give in during firing may ruin both the kiln and the ware. To avoid these problems tests can be done to ensure that the materials will withstand the severe conditions to which they will be exposed during many cycles of firings. Therefore before trusting a refractory raw material or a refractory product, say a firebrick, some simple tests should be carried out. Simple tests of clay supplies can also tell us whether we get the clay we expected and which may havebeen paid for dearly.

Mortar rcripes

The following recipesare examplesmeasured in weight: 38

1 ’

Japanese mortar quoted from F. Olsen “The Kiln Book” (p. 18) From D. Rhodes “Kilns” (p. 94)

1.6.1 High temperature testing

Test kiln

Ceramic institute

in caseno high temperature kiln is available, a small test kiln could be constructed. In extreme cases,where there are no proper refractories available for the construction of a test kiln, (this was once experienced by the author in Africa) the test kiln, built of the untried refractories and fired to as high a temperature as possible, becomes the test itself. A small test kiln is also useful for firing glaze and body tests and the one shown in fig. 146 is not expensiveto construct. By changing the firebox arrangement it dan be fired with firewood, oil or coal (p. 73-87).

The first thing we want to know is: can the clay withstand high temperatures? For this, a kiln which can withstand temperatures of 1300-1400 “C would be ideal for testing. Few potters will have accessto such a kiln, ’ but a sample of the clay could. be sent through local authorities to the national geological department or ceramic institute which will normally be interested in gaining information about suitable clay sources. Production kiln

Quicker results could be obtained by firing the test piece in the flue, in front of the firebox, or on top of the bagwall of a potter’s kiln. The temperature may not be 13001400 “C but it is most likely the’highest temperature the material will have to withstand in practice. Fig. 146:

1.6.2 Refractory materials and bodies

In most casesit will already havebeen established whether or not the type of clay in question is suitable for high temperaturesand the individual potter or local pottery development centre will only need to check the

Test kiln

IJric I?s

firelrricks

.bm..eeoe

quality of clay supply and refractory body mixtures. The following tests should be carried out with new batches of clay. Sampling

The clay to be tested should be collected from at least four diffe:ent placesat the clay deposit or from where the clay has been dumped. The four samples of about equal size are mixed well on a swept concrete floor. The sampled clay is then divided into four equal portions. Two portions opposite each other are set aside and the other two are mixed thoroughly. This process of dividing and mixing should be repeated at least four times. This method is called quartering (fig. 147) and ensuresthat the final sample is representativeof the bulk of the clay. Moisture con tent

A sample of about 100 g is weighed on a scale. The weight Wm is recorded and the sample is heated to 1IO-200 “C for an hour so that all water evaporates.It is then put on the scale again immediately and the dry weight Wd recorded. Moisture content in per cent

= Wm-Wd )(1()(-j

Fig. 147: The method of quartering: 1. The sample is mixed well. 2. It is then divided into four portlons. 3. Two portions are removed. 4. The remaining two portions are mixed well and another cycle of quartering can start. Fig. l-48:

Test bar for measuring

shrinkage

Wd When the clay is purchased by weight the moisture content shows how much water has been paid for. When weighing the clay according to recipes, excessiveamounts of water in the clay should be compensatedfor. Shrinking test

The clay is mixed with water to normal plasticity and S-10 test bars measuring 1x2x 12 cm are formed. A wooden mould makes this job more easy.Two parallel lines exactly 100 mm apart are marked across all the test bars. While drying, the test bars should be turned over now and then in order to avoid

warping. When the test bars feel dry the distance between the two cross-linesare measured in mm on all bars and the amount of dr$ng shrinkageis found: Drying shrinkagein per cent = lOO--Drylength x 100 100 As the distance was 100 mm the shrinkage in mm is equal to shrinkage in per cent. After firing the test bar to the highest temperature possible additronal shrinkage is measured m mm and recorded as: Firing shrinkagein per cent =: Dry length - Fired length x 1oo Dry length Total shrinkage in per cent = 100 - Fired length in mm. The drying shrinkage indicates to some degree the plasticity of the clay. A large drying shrinkage means that the plastic clay could absorb much water, which in turn indicates fine clay particles. The figure for drying shrinkage should be compared with figures of former supplies to seeif the present batch is of the samequality. The firing shrinkage indicates how fusible the clay is. A high shrinkage normally means a lower melting point. The total shrinkage of refractory bodies tells us how much bigger we should make OUT moulds. In case we want OUT slab to measure30x30 cm and the total shrinkage of the clay/grog mixture is 8% then our mould frame should measure: 3o+3ox8 --cm = 32.4 cm on each side. 100 Softenirlg point

The test bars are placed in the kiln as showrl in fig. 149. The test bars should be supported so that the free span equals the distance between the cross-lines of the test bar. If possible cones should be placed next to the test bars to show the temperature. After firing the amount of bending is Compared

Fig. 149: Setting of test bars for fiiing. The bending of the bars is compared with the bending of cones.

with the cones and results from former tests. When testing a new clay the test bar should be placed so that it can be viewed through a spyhole and the approximate temperature at which bending starts is noted. Pore water

After measuring drying shrinkage some of the test bars can be used for measuring the amount of pore water. Pore water is the water that is left in the clay after the water of plasticity has evaporated. The pore water will only leave the clay above 100 “C during the smoking period of biscuit firing (see p. 113). First the weight, Wd, of the dry test bar is found and recorded and the test bar is heated to 1lo-200 “C for one hour. Immediately after that the test bar is weighed again, weight Wp is recorded and the percentage of pore water can be computed: 41

Pore water in per cent = Wd-Wp xl(Jo WP

quality of new batches of clay with former supplies it is accurate enough.

The pore water percentage expresses the fmenessof the clay particles or the plasticity of the clay. The test is simple and is good for ensuring that new supplies of clay do not contain too much sand. The following pore water contents are typical: kaolin 1.5 %, fireclay 3.5 %, ball clay 4.1 %, brick clay 2.2%, bentonite 14%

1.6.3 Refractory items

Plasticity

The results of drying shrinkage and pore water content tests discussed above are an accurate indicator of a clay’s plasticity. However, the first and most simple test for any potter is to wet a small portion of the clay in the palm of his hand and get the “feel” of it. The clay is rolled into a pencil shapeand the more this “pencil” can be bent into a ring without rupturing, the more plastic the clay is.

Particle size

A quick test of new clay supplies can be done by making the clay into a thin slurry and screening it through one or more very fine sieves. A 200 mesh sieve holds back particles bigger than 0.0076 mm. The residue on the screenis dried and put on the scale.If the weight of this residue is called Wr and the dry weight of the total sampleWC, Size less200 mesh in per cent = Wc-Wr WC

x1(-J(-)

This figure can be used to check the amount of sand in the clay. Some fine sand will pass a 200 mesh sieve, but for comparing the 42

’ ‘Spalhg count ” test

Besides possessingrefractoriness our refractory products such as firebricks and saggars should be able to withstand many cycles of heating and cooling without crackiug or spalling. The ability to withstand thermal shocks is tested by heating a standard-size (appr. 23 x 11.5 x 6.5 cm) firebrick to around 900 “C. The hot firebrick is then picked out of the kiln and plunged into water of room temperature. This is repeated until half of ‘the brick measured by weight has cracked away due to this shock treatment. If the brick can endure 10 cycles of such heating and cooling it is very satisfactory. The clay body for saggars or slabs is formed into bricks and tested in the sameway. Water absorptiort

If the clay body of saggarsor bricks becomes too dense ‘it will be more prone to cracking due to thermal shocks. The more dense a body is the less water it will absorb. So the density (or porosity) can be measured by soaking a piece of the fired clay body in water for at least 24 hours. It is then taken up and after its surface is wiped dry its weight, Ww, is found. The soaked test piece is then heated at 1lo-200 “C for one hour and its dry weight, Wd, is recorded. Porosity or mom accurately the water absorption can be estimated. Water absorption in per cent

= Ww-wd ; 1()(-J

Wd For saggarsand slabs a figure of 18-25 % is reasonable.

2. Kilns

2.1 Development of kilns A kiln may be described as an enclosure to cont& heat. Potters use i? to fire their pots and they havedevelopeda countless number of different kiln types, each one reflecting the demands of local markets, tradition, skills and materials. Even so the basicsof all ceramic kilns are the same; heat is introduced into the enclosure surrounding the pots. Some heat is lost through the walls or is carried away with the combustion gases,but as more heat is introduced than escapes, the temperature rises and the pots will mature. 2.1.1 Bonfire kilns The oldest type of kiln, dating back more than 10,000 years, is the bonfire kiln. These kilns are still widely used for firing tradiFig. 2-I : Bonfire

kiln

tional unglazed red ware (terracctta) because they are still the most suitable for small-scaleproduction of low-fired pot!: J-. This is due to the fact that no investment is needed for a permanent kiln, that the firing at most takes a few hours and that cheap and readily available fuels such as straw, grassand cowdung can be used.

Sukuma potters

The Sukuma women in Western Tanzania often use split roots of sisal as a fuel (fig. 2-2). The roots produce intense heat and the firing takes no more than half an hour. The pots are fired no higher than 700 “C. This is an advantagefor pots made for cooking over an open fire becausethe clay has not started to sinter and its open structure can more easily adjust to the thermal shock of being put over a fire.

Fig. 2-2: Sukuma potters firing their pots with sisal roots in a bonfire kiln. Bujora, Tanzania. Fig. 2-3: pots.

Bark

“glaze”

is applied

to the still

hot

D

The pots are dried in the sun the whole day so that moisture in the pots will not crack them when they are exposed to the sudden heat. The pots are raised a bit on a layer of broken pots and some sticks of sisal roots are placed in between. About two layers of roots are placed around the small heap of pots and set on fire. Another layer of roots is added during the fire and sometimes more where the fire consumesthe roots too fast. Before the pots have cooled they are raked out of the smouldering fire and beaten with branches (fig. 2-3) dipped in a bark soup. The carbonaceous matter of the extract sticks to the pots and givesthem a partly water-proof surface. 44

Fig. l-4:

Straw-fired

kiln in Thimi,

Nepal

Nepalese po;ter

In fig. L-4 a potter in Nepal is preparing his kiln for firing. Behind him another kiln is opened and the pots are ready to be sold. The pots are stacked in a big heap with straw and in the lower part firewood in between. The pots are finally covered with straw, broken pots and an insulating layer of ash on top. Holes in the bottom of the kiln allow air for combustion to enter. The fire is lit in the bottom of the kiln and then gradually works its way through the heap. This kiln illustrates a development from the Sukuma kiln as it has the heat travelling up through the pots, vent holes making control of the tire possible and an insulating layer for better containment of the heat. Firing temperature may be 150 “C higher compared to the Sukuma kiln.

Fin. 2-5: Communal tapur to produce Nepal. I

shed cn;Mes potters in Bhnkpots during the monsoon in ,Bgsi,i:

Fig. 2-6: This kiln is constructed with broken pots forming walls, fireboxes and flues. The first layer of green pots is stacked on top of the flue pots. Sinde. Burma.

Straw, pieces of broken pots and clay form the outer layer. Vent holes are left in the crown of the setting. Firing is carried out by stoking firewood in the four fireboxes. The combustion gasesand heat go up through the setting and leave through the vent holes at the top. Kilns of this kind are called up draught kilns. The use of fireboxes and flues, though simple, allows much better control of the firing. In the beginning a very small fire allows the pots to dry out completely and at the end of the firing heavy stoking will ensure 3 high temperature. The hot gases and flames from the fire circulate all over the kiln creating 3 more even temperature and utilizing the heat better.

2.1.2 Sinde updrought kiln 2.1.3 Bangladesh updraught kiln

The kiln of the Sinde potters (fig. 2-6) has no permanent structure. Four fireboxes, one on each side, are constructed by the setting of pots. A bottom layer of once-fired, partly broken pots works as flues through which heat from the fireboxes spreads to all corners. The green pots are stacked on top and other cracked pots are built into 3 kiln wail.

Fig. 2-7 : Top layer of the Sinde kiln is laid.

46

In fig. 2-8 3 simple up-draught kiln is nearly ready for firing. Once-fired pots are serving 3s a kiln wall as with the Sinde kiln, but this one has 3 permanent firebox dug out under the kiln. Fuel is cowdung stuck on bamboo sticks as this area, the western part of Bangladesh,has hardly any firewood to offer.

Fig. 2-8: Semi-permanent up-draught kiln Rajshahi, Bangh~desh. After smoking a layer straw and mud is plastered on the outside.

in ol

gases enter the kiln chamber through the perforated floor and leaT{ethrough holes in the crown. Great skill is neededwhen setting the ware so that space is left for the gasesto pass in a way that ensureseven temperatures. At cold spots more spaceis left so that more hot gaseswill pass there while the spots tending to overheat are stacked more densely.This kiln is fired to 900-1000 “C.

Fig. 2-9: Ancient

up-draughi

kiln from Greece

2.1.4 Permanent up-draught kilns

In the Near East up-draught kilns with permanent outer walls were developed(fig. 2-9) and this type of kiln spread,with migrating potters from Persia to’ India. It is still widely used and fig. 2-10 shows an improved type of up-draught kiln which was constructed by Indian advisersin Tanzania. Stoking is done through firemouths at two sidesan! the hot

Fig. 2-10: Square up-draught

firemouth Fig. 2-11: Setting of pots in an up-draught to be done so that the hot gases rise evenly the pots.

kiln has through

kiln, Singisi, Tanzania

Glazed pots

The permanent structure makes packing of the kiln easier and the walls retain and reflect the heat better so that higher temperatures can be reached. The drawback, compared to the lighter kilns mentioned above, of the heavy kiln structure is that 3 great deal of fuel is used for heating the walls along with the pots. The permanent kiln chamber makes it possible to stack glazed pots properly and this may be the main reason for constructing a permanent kiln. 47

2.1.5 European up-draught kilns The up-draught kiln originating in the Near East spread to Europe where it was further developed and reached its perfection with the bottle kilns (fig. 2-12). These kilns were widely used untii the beginning of this century, when they were replaced by downdraught kilns. The bottle kilns could be fired up to 1300 “C. Damperson top of the dome could be opened and closed for directing the draught. That enabled the skilled fireman to achieve fairly even temperatures. The ware was placed in saggarsto protect it from the Fig. 2-l 2: Bottle kiln with its innovations: chinb nay. fircbrirks and iron grates for burning coal

combustion gases.Often a biscuit chamber over the main chamber was added so that the otherwise wasted heat was used for biscuiting. Rejkactories, grates, coal, chimney

These up-draught kilns were originally developed in Germany, by the beginning of the 17th century, in an attempt to produce porcelain which was then only produced in China. The 1300 ‘C needed for porcelain was reached by constructing the kiln with firebricks and by firing coal on cast-iron grates. The grates made it possible to speed up combustion of the fuel and reduce the intake of excessair. A chimney placed on top of the chamber creates the extra draught needed to draw combustion air through the grates. Fig. 2-13: Cross-section

of a hovel kiln

Hovel kiln

A variety of the bottle kiln is shown in fig. 2-13. It works in the same manner but a hovel enclosesthe kiln and protect: it and the workers from the weather. The kiln itself was cheaper to construct as it did not need to carry the weight of the chimney and the hovel could be constructed entirely from common red bricks. The potteries of North Staffordshire, England, were famous for these kilns which literally dominated the skyline around Stoke-on-Trent. The hovels could be up to 21 m high. Limitations o~‘tt‘tcp-druugiltkilns

By the turn of the century the up-draught kiln was considered outdated. A ceramic expert Mr. E. Bourry’ wrote: “Intermittent kilns with up-draught ought to be condemFig. 2-14: Hovel kilns seum, Stoke-on-Trent

at Gladstone

Pottery

Mu-

Fig. 2-15: up-draught

Chimney kiln

effect

creates hot spots in ;1n

ned. They have the double effect of being wasteful and giving an unequal distribution of heat . . . and only deserveto be forgotten.” The up-draught kiln is wasteful becausethe hot combustion gases rush too quickly through the kiln setting, so that the heat of the gaseshas little time to be transferred to the ware. The bottom of an up-draught kiln tends to become hotter as the hot gasesstrike here first. Furthermore, in the setting of the ware some places will be more open and the hot gaseswill tend to passthat way. That makes these spots hotter whereby even more gases will be pulled that way just like a hot chimney pulls better than a cold one. The updraught of the gasessimply creates this tendency of making hot spots even hotter. These drawbacks led to the invention of down-draught kilns. 1

“A Treatise on Ceramic Industries” by Emile Bourry, p. 211. It is still true except that in recent years up-draught kilns fired with gas and constructed with fibre refractories have been able to overcome these problems.

49

2.1.6 Down-draught kilns

In a down-draught kiln the hot gasesfrom the fireboxes circulate to the top of the kiln chamber, are then pulled down through the setting and leave through flue holes in the floor. Under the floor flue channels lead to the chimney (fig. 2- 16). Ever1temperatures

Hot air rises so the downward draught of the hot combustion gases tends to avoid the hot spdts and seeks out the cold spots Fig.Z-16: lhwn-druught chawwls undcr itic !luor

kiln wth

tlue

I .

where the downward pull is stronger. In this way the draught will by itself evenout temperature differences. Bug walls

A wall, named a bagwall, at the inlet from the fireboxes directs the hot gasesupward. In case the top of the setting tends to be too hot the height of the bagwalls is lowered and vice versa. Sometimes holes in the bagwall help but the holes weaken the wall and it may collapse during firing. I

draught kiln, simply because they have further to go. So more heat is transferred to the ware and consequently fuel is saved.As the hot gases leave the kiln chamber at ground level it is easier to let them pass through another chamber or several chambers before entering the chimney.

A chimney for down-draught has to be tall to create a strong pull, which is required to force the heat downward especially if more chambers are added. The Bujora kiln (p. 53) has an up-draught biscuit chamber which at the sametime servesas a chimney. Fig. 2-17: The downward draught avoids the hot spots and seeks out the cold spots in the kiln setting.

2.1.7 Khuja kiln Heat ecormny

The combustion gasesspend a longer time inside the chamber, compared to the up-

The Khurja kiln is a typical example of a coal-fired down-draught kiln of European design(fig. 2-18).

Fig. 2-18: Circular

India.

coal-fired

down-draught

kiCn. Khuja.

insulating

firebricks

N-

flue channel I

grou;evel

to chimney

I

Im

Fig. 2-19: Khurja down-draught kiln a) side elevation, 11) ground elevation showing nels. The details for this kiln have been obtained from “Status Report on Ceramic published by Central Glass and Ceramic Research Institute, Calcutta, India.

flue holes and chanIndustry at Khurja”,

2.1.9 Bujora downdraught

This kiln was constructed with a second chamber which works as an up-draught kiln and chimney. When the first chamber reaches 1240 “C the second chamber would be 800-900 “C which is sufficient for firing biscuit ware and common red bricks. The top third chamber can be used for calcining feldspar and quartz for glazes and clay bodies. Cllitnnty chamber .4s firebricks, of which a normal chimney would be built. were made of kaolin which

Fig. Z-20: 30 m3 down-drx@t struction. Muyangonc. Burms

kiln .xndcr recan-

2.1.8 Mayangone kiln

The kiln in fig. 1-20 was originally woodfired but has recently been converted to oil. It was built in 1914 after a German design that has five flue channelsin the wall. These help to transfer some of the heat of the flue gasesback to the chamber through the wall (fig. 2-23). Ihr outer kiln wall carries the weight of the top chamber and chimney and the kiln is reinforced with plenty of mild steel bands. The flue channel under the floor can be cleaned from the outside, which is a good idea. The kiln fires to cone 7 (.1250 “CI and the temperature difference between top and bottom is xnth I --I ‘1: cones(,30--50 “C).

Fg. Z-21: Fust chamber of Bujora 011 pipes lead to the three fIreboxes.

kiln. Water and

Fig. Z-22: l‘he Bujora kiln wen from the other side with Its chimney bmber to the right

%q e %u!+e)s aql JO Ilnd aql aseam! 01 ~apro u! Iauuey3 afy ayl ur I![ serriml lleuxs uarpv,

v

ICauuqy~

*luaprJJns

lou

seM

%u!q

alewuols

aq*

JO li2ay alsells ayl am u! larl)mJ pasy aq pp103 laqureq3 puo3as ayl JO arn)eladural ayl jeya OSsraqurey:,o&l alp uaaM$aq(p:-; ‘S[pM

aq1 II! qauuntp

*Sg) ~auuey~anu ayl v paaeld aq pp103 lau -mq aleId-d!Jp v */Cellnoawes aql IOJ amn

3Jout Supy iuearu raqmy3 puosas e 'asen Aue u] *sy3pq uounuo3 Jo saqu.my3Aauwly:, ayl ppnq 01 ajes $1 apew laiaump apy.y ap!M ayL *~aqumy:,puo3ase oiu! paurn pm papuedxa SeMAauw!y3 atp ‘ahyuadxa set arQ

q,!M

apnlu S!u[!y auom2A:cly al[L : [Z-Z ‘%!.J

Fig. 2-24: Two-chamber Bujora kiln, cross-section. The first chamber is provided with three fireboxes for oil firing but fireboxes for firewood or coal could be used as well.

sulating

firebricks ordinary -a-

brick!

- ash layer

flue channel

2.1.10 Cross&aught kilns Cave kilns

The cross draught kiln originated in the Far East and aswith the up-draught kiln this type of kiin must have developed gradually from the open bontire. Potters found that by enclosing the fire higher temperaturescould be reached; instead of building up a wall around the fire the potters hollowed out a caveinto a bank of clay (fig. 2-25). The lower end served as a firebox and the hot gaseswere carried through the ware across the cave chamber and out through the flue hole. Cave kilns are not in use any more, but old kilns have been found by archaeologists.

Fig.2-25:

Cave kiln dug out of a clay bank

Fig. 2-26: Reconstruction in Thailand

of old cross-draught

kiln

Stoneware temperatures

Such simple kilns were capable of firing stoneware. The cross-draught through the ware transferred more heat to the ware compared to up-draught and the fully enclosed kiln chamber retlined the heat well. The kiln developed into a variety of crossFig. Z-27: Two wood-fired

kilns seen from firehox

side

draught kilns. Fig. 2-26 shows a reconstruction of a kiln type which was used in Central Thailand 700 years ago for firing glazed stoneware, and similar kilns, though bigger, are still used throughout South-East .Asia. Fig. 2-37 shows a wood-fired kiln used for firing celadon stoneware. It has no separate firebox, but the front part of the kiln is 0.5 m lower and servesas a fireplace. The floor for the setting of ware slants upward and the kiln chamber narrows towards the exit flue. That helps to create a more even firing temperature. The faster the flow of hot air the more heat will be transferred to the pots. Close to the fireplace the air is hot but moves slowly, whereas towards the back the air is cooler but is moving faster due to the narrowing kiln chamber. Some kilns of this type have stoking holes at the sides so that stoking is done here towards the end of the firing.

2.1 .I 1 Tube kilns The cave kiln, supposedly, was made ever longer until it developed into the long sloping tube kiln about one thousand years ago. Tube kilns tie up to 50 m long and are used for both earthenwareand stoneware.On p. 92 a tube kiln is seenfrom the firebox end. The kiln chamber is a long uninterrupted tube with an exit on top. The tube is ftiied with pots, traditionally in an open setting, but now also with saggars(fig. 2-28). The fire is started in the firebox and the combustion gasesgo through the whole kiln to the top exit and transfer all of their heat to the ware on the way. When the lower section of the kiln has reached maturing temperature stoking into the tube is begun through side holes just above the matured section (see p. 7 1). The combustion air enters through the firebox and is very hot when it reachesthe firing zone. In this way the firing zone slowFig. 2-29: Upper section side of the arch.

df a tube kiln.

An entrance

Fig. 2-28: Snggars set in a tube kiln under repair

ly moves upward until the whole kiln is fired. When the upper section is fired the lower section has already been cooled considerably by the intake of combustion air. The difference in height of the exit flue and the inlet at the firebox is often enough to create sufficient draught through the kiln. However, some tube kilns have a low chimney as seenin fig. 2-29. is made for every

I-

5 m. Stoking

. .

..,,-.,__

holes are seen at the

_

57

Fig. Z-30: Cross-section

of a chamber

kiln

2.1.12 Chinese chamber kiln

In China the tube kiln was further developed by breaking up the long tube into separate but connected charrbers (fig. 2-30). The fire is started in the firebox and the first chamber is fired as other kilns. When the desired temperature is reached in the first chamber, say 1280 ‘C, the second may be around 1100 “C and the third around 700 “C. Firing is continued by side stoking in the second chamber through openings in the door. The temperature in the second chamber rises rapidly becausethe combustion air is preheated from passing through the first chamber. The preheated air is so hot that thin sticks of wood fed through the stoking holes burn instantly.

kiln is about 20”. The Chinesechamber kilns could have up to eight chambers and would be stacked with ware produced by many individual potters. The largest kilns could be up to 400 m3 in total kiln space. 2.1.13 Champaknagar chamber kiln

Fig. 2-31 shows a three-chambered woodfired kiln at a pottery school in Champaknagar in Bangladesh.Identical kilns are built by groups of students when they set up their own potteries. According to the size of the group kilns are built with two or three chambers and more chambers c;lil be added later as the production increases. Earthenware

Setting

In each chamber a bagwall or saggarsforce the heat upwards after which it is drawn down through the setting and across to the exit flues leadng into the next chamber. The draught is normally created by the upward slope of the kiln. The slope of a chamber 58

The kilns are fired to 1100 “C with an open setting on kiln shelves. Eeach chamber is about 3.5 m3 and takes 600 mugs. Ordinary red bricks are used for construction throughout, but there are plans to provide the kilns with an inner lining of insulating firebricks in order to improve the fuel economy.

Fig. 2-3 1: Three-chambered wood-fired kiln under construction. The !irebox to the right and the chimney ;lt the other end are not yet re:ldy. Ch;lmp~knagar, Bangladesh.

Firing

The firing is started at midnight so that the last part of firing takes place during the day in order to minimize the risk of fire in the villages. The pots have been biscuit-fired by traditional kilns similar to the type shown in fig. 2-8 and so there is no need of a smoking fire. During the first three hours a layer of embers is built up in the firebox. After that firing is done at fuuilrate until the temperature reaches 1100 “C in the first chamber at 8-10 am. Three dampers in the bottom of the chimney are used for eveningout temperature differences sidewise. The stoking is then moved up to the next chamber and the firewood is fed through stoke holes at both sides above the inlet from the lower chamber. Each additional chamber reaches1100 “C after about two hours’ stoking.

Firewood

The first two chambers consume 2200 kg firewood and each additional chamber about 500 kg. Unfortunately the firewood is not properly seasonedso heat is wasted drying out the extra water in the firewood (p. 64 f.). Fig. 2-32: Two-chambered kiln built with sun-dried bricks. Suvapur. Bangladesh.

Fig. 2-33: Two-chambered

wood-fired

kiln. Champaknagar,

Bangladesh.

view from firebox-side

I l--l

I : #’ i”“?,

I I\ \\\

side view

flue holes

insulating

Im

1

firebricks

ir

Extra chamber

The small extra cost of firing addirional chambers makes it tempting to add several more. The additional chambers would also reduce the size of the chimney which is 4.4 m for the twochamber version. However, a huge kiln capacity would also mean longer periods between figs and would mean that more space for storing pots awaiting firing would be needed. It may also be difficult to set aside enough money for the production costs in the longer time between making pots, firing and selling the finished ware. Construcriorr

It is better to start with a few chambers while the pottery workshop is starting up; later as production and confidence grow additional chambers can be added without much interruption to production. It is better to plan for future expansion when designing and constructing the kiln, so that sufficient

space is left to build on. In case the kiln is built on a slope it is easier to add extra chambers at the firebox end as the chimney is a larger structure to dismantle and reconstruct. Firebox

The firebox shown in fig. 2-34 is made very wide because the unseasonedfirewood has to spend longer time drying in the flrebox compared to properly dried firewood. Other types of fireboxes as described under fireboxes (p. 73-87) can be used as well. A more rational solution of course would be to seasonthe firewood properly. However, small village potteries have no money to invest in a stock of firewood sufficient for drying 4-6 months. It is costly to be poor. Seljkupporting

The chamber kilns are constructed without any iron frame supports. The structure sup ports itself as the chambers lean onto each other.

Fig. 2-34: Champuknagar

firebox

61

2.1.14 Sumve cross-draught kiln

The cross-draught principle of the chamber kiln is used in a small waste-oil-fired kiln constructed in a small viilage pottery in Sumve,Tanzania. The kiln is fired to 1250 “C and uses an open setting. It is constructed with self-made insulating firebricks with an outer wall of common bricks. The chamber is constructed as a catenary arch (see p. 102) which makes the structure self-supporting. The capacity of the kiln is rather small but for newly started workshops it is fine. This kiln could be expanded by adding more chambers as is done in Champaknagar. Fig. 2-36: Stoneware

kiln with about

1 m3 capacity

Fig. 2-35: Waste-oil-fired kiln in Sumve, Tanzania. To the right an oil heater.

(cross-draught

kiln)

ground-plan

cross-section damper

Im

62

~~~,.//.;‘/.~.;//~~~..~.‘,“‘.‘“.’//”.’”/.’ p,.//://:m \ solid firebricks

i:;::

2.2

Choice of fuel

from the pottery the cost of hiring a lorry may make this fuel very expensive. Or in case coal can be bought from a government store the cost of employing a person to do the necessarypaperwork, etc. will also add to the fuel cost. The different fuels have different heating values and this should also be taken into account, e.g. 1 kg of firewood may only produce half the heat of 1 kg of coal (see appendix).

Nearly everywhere the cost of fuel for firing kilns is the single biggestcost of ceramic production. In some areasthe cost of fuel simply rules out the production of modem pottery and only traditional pottery fired with agricultural waste materials is economically possible. Kilns heated by gas or ciectricity will not be described here because these fuels are seldom available or their cost is prohibitive. (This might change in the future when big hydroelectric or natural gas projects will make these types of energy more easily available and cheaper.) That leaves us with three main sources of fuel: firewood (and agricultural waste), coal and oil.

Table 2-1 is an illustration of how to compare fuel costs. This comparison is based on the estimated fuel consumption for the firing of a two-chamber kiln of Champaknagar type. In this example firewood turned out to be the cheapestfuel, but if the source of coal had been closer it would have been less costly to transport and could in that case become the chosen fuel. The cost of coal in this example also includes $ 12 for employing a person to acquire the necessary licence to purchase coal from a government store. In areaswith a higher cost of labour, firewood Gould become more costly due to the heavy work involved with felling the trees and cutting the firewood.

Cost and supply

In many areasonly one type of fuel is available for potters. However, those fortunate enough to be able to choose from several types of fuel should consider which fuel will serve them the best by comparing (1) the cost of the fuels and (2) how reliable the supply is.

SUPPlY

A low-cost fuel which is seasonalor of unreliable supply may turn out to be costly due to delayed things. These in turn will causecuts in production and income. In order to secure a regular supply it may often be better to accept a higher cost of fuel than

Total cost

The cost of transport and the time spent on buying the fuel needs to be added to the actual market price, e.g. sawdust may be very cheap at the sawmill but if this is 50 km Table 2-1

Fuel

Heat value

Fuel needed

(US $1

Drying, storage, preparing, firing (US S)

Total (US $1

30 20 45 80

12 2 2 14

94 424 150 142

Net price

Transport

(US $1 Firewood Fuel oil Wustc oil

CO31

3400 9000 10100 7720

cd/g cd/g c&l/g Cal/g

2200 893 795 970

kg I I kg

.

52 402 103 48

63

suffer the results of an insecure supply. If the supply situation is difficult it is better to arrange fireboxes which can burn two OF more different fuels. For example it is easy to place drip-plate burners in a tirebox for coal or firewood. The additional cost of making two firing systemsmay be recovered in one or two firings.

2.2.1 Firewood

Formerly fuewood was the main fuel all over the world but today in the industrialized part of the world firewood accounts for only 0.4% of fuel energyused,while in the developing world firewood still accounts for 25% of the energy used’. In the poorest countries about 40% of the energy is from wood. That figure reflects the fact that oil products and coal are too expensive and often not available to the majority of people in the developing world. Therefore, many potters, especially those in rural areas, will continue to rely upon firewood for firing their kilns. Ash coburs

Firewood is easily capable of heating kilns beyond 1300 “C if desired, and it also produceslong flames which help to even out the temperature inside the kiln. Firewood ash will not normally harm glazes, apart from slightly changing their colour. Some potters even try to promote this colour effect for its decorative quahty. If this discolouration is not desired the ware should be fired in saggars.

Fig. 2-37: These saggers are provided with holes that will allow the effect of ashes to reach the glazed wure.

Heat value

The softwoods such as fir and pine have slightly more heat value per kg compared to hardwoods such as teak and oak. The weight per volume of oak or teak is about double that of pine (seeappendix). The hardwoods burn more slowly while the light softwoods burn much faster and with longer flames. Usually hardwoods are burned in the initial stagesof firing while softwoods are used near the end when a fast releaseof heat is needed to raise the temperature. The slower heat releaseof the hardwoods can be countered by splitting the wood into very thin sticks. Water content

’

Arnold & Jongma “Fuel, Wood and Charcoal Dexkpiqz Countries” (FAO. Rome)

in

When wood is freshly cut it contains 3050% water. Wood with so much water not

dry season.Properly dried firewood still contains lo-15% water. Storing

Fig 2-38: Special axe for splitting firewood. The axe does not cut the wood but splits it by impact. It is not suitable for splitting wood with long fibres.

only bums badly but a lot of the wood’s energy will be used to turn the water into steam. The wood should be stored until it is completely dry on the surface as well as within. In temperate climates this will take a year while in tropical countries the firewood should be allowed to dry throughout a

The potter will need to keep a stock of firewood big enough to last for six months or one year depending on the prevailingclimate. The three-chamberedkiln from Champaknagar (p. 58 f.) uses about 2.3 tons to fire to 1100 “C. It is loaded with 1800 mugs and is fired nearly every third week and so a stock of 20 tons of firewood will be neededin this case.Some potters may be able to buy wood which is partly dried but one can never be sure of this and so it is better to buy fresh wood which is easier to split. When settling the price for the purchase of firewood by weight, take into account that the fresh wood weighs about 30% more than dry wood. Normally it is much cheaper to buy large amounts of wood by the lorry-load. This also Fig. 2-40: A solid chump of wood half-buried in the ground is the proper base for splitting firewood.

Fig. 2-39: Firewood stocked so that air can pass easily through the stack and dry the wood

65

allows the potters to cut the wood into suitable sizes.The cutting and splitting of wood is much easier while it is still fresh. Sticks about 60 cm long and 3-5 cm thick are needed for the last hours of stoking, while thicker ones will be fine until then. Splitting the wood makes it dry faster as does stacking the long sticks so that air can pass through the piie. Bamboo is an excellent fuel although it is usually reservedfor construction purposes. Fire hazard

Potters often place the firewood for the next firing on top of, or on shelves,above the kiln during a firing (fig. 24 1). The heat from the kiln dries out the wood completely thereby further reducing the cooling effect of the moisture in the wood. However, great care must be taken to prevent the wood from catching fire. Fig. 2-4 1: Split bamboo

Plan tiq trees

In some areas there are large forests with plenty of trees and it may seemthat there is no need to worry about :i lack of wood for fuel. However, evenpotters in theseareasmay after only a short time find there is not enough firewood becausethe demand for wood is so great. The price of wood goesup as firewood is cut further and further away. A family uses about 4000 kg of firewood each year for cooking alone. Therefore, one single viilage may soon use all the trees in the nearby forest if no new trees are planted to replace the ones which were cut and burned for fuel. Even though the potter may face no trouble in getting firewood for the time being, these fortunate conditions are unlikely to last forever. If at all possible, potters should try to secure their source of firewood by planting their own trees. In heavily populated regions land is scarce and expensive and so potters will be unable

sticks are dried on top of u sloping tube kiln.

-

This stack represents

a year’s supply

Fi_e. 2-42: The big stack represents B family’s annual vecho-Institute. Fuel-Saving Cookstoves. GATE/Vieweg,

use of firewood 1984. p. 6).

for cooking

(drawing

from:

Apro-

to buy or lease land for growing trees. In other places, however, potters may through local authorities be able to lease fallow land where trees can be planted. Often local development authorities offer seddlingsfree of chargeto villagers. It may seem an overwhelming task to start planting a forest. but in fact the forest does not have to be very large. Where a three-chamber kiln like the one at Champaknagar is fired every three weeks it will consume 40 tons of firewood annually. Azcording to someestimates’ a forest covering i--2 hectares of land will produce this amount of wood every year. In tropical areasa tree such as a eucalyptus grows so fast that it can be cut for firewood after only two or three years. Some trees will shoot again from the stem after cutting and so the trouble of replanting is dispensed with. The right choice of tree speciesfor growing firewood depends on local &mat,. and soils. All countries have a forestry department

which should be able to advise on which trees would be most suitable in a specitic area’. 2.2.2 Agricultural waste

All agricultural waste products are bulky fuels. They take up a lot of spacecompared to the amount of heat they releaseon buming. The main attraction of waste products is their cheapness,trsnsportation often bemg the only cost. In some areas agricultural waste products are already used for cooking or as fuel by local industry, whilst in many other areas these by-products are just dumped and are free for use. *

2

30 m3 of wood !solid volume) is the average annual production per hectare ( lOOx 100 m) for B well managed plantation. (FAO Report: RAS/ SOlOOl, H;lngkok 1984). Further information ‘can be obtained from: Coordinator. Wood Energy Programme, Forestry Department, FAO Rome. Via delle Terme 111Cxwalls, 0 1000 Rome, I My.

67

Sawdust

Sawdust has the sameheat value as the wood from which it was cut. It is an efficient fuel when used with the right firing system (p. 76). The main problem is to keep it dry becauseit soacksup moisture like a sponge. Rice husks

Milling of 66 kg of paddy produces 10 kg of rice husks. The heat value is nearly as good as for sawdust but this fuel has a high ash content. Some rice mills bum the rice husks for steam-powering the mill and drying the rice hulls and so they may only have a little left over to sell.

rests. Peat can be described as the first step in nature’s production of coal. It is normally only covered by a thin layer of soil. Winning

The peat contains about 90% water when it is dug or rather cut. The soft massis cut into blocks (20x5~5 cm) which are first laid out on the ground for drying. As soon as the blocks can be handled they are stackedinto piles in order to acceleratetheir drying. Drying may take several months anti the airdried peat blocks will contain 20-30% moisture. Winning of peat requires only manual tabour and a few tools. Heat value

Other vegetable wuste

,The following materials can be used during the initial firing of the kiln as an additional fuel: - Peanut hulls; very bulky but have the sameheat value per kg as wood. - Bagasse;the crushed sugar cane after the sugar juice is extracted. 130 kg sugar produces 100 kg wet bagasse.The bagassehas to dry for a couple of months. With 15% moisture content it has a heat value close to firewood. - Sisal; production of 1 kg sisalfibre leaves 30 kg waste which after drying is a usable fuel. The roots of the sisal plant also burn very well. - Straw from growing paddy, corn, etc. is often used for firing traditional unglazed pottery and can he burned in the fireboxes of a pottery kiln provided rhe straw is tightly bundled.

2.2 3 Peat

Peat is a spongy mass of vegetable matter formed by the decomposition of ancient fo68

The properties of peat are still close to those of firewood and peat can be burned on firewood grates although it needsslightly lesssecondary air compared to firewood. The heat value of air-dried peat is close to that of firewood. 2.2.4 Lignite Lignite is the step between peat and real coal. Lignite may be brown or black and it still has a wooden-like structure. Some lignites are cal!ed brown coal. The lignites differ considerably in their moisture contents and heat values with some being close to peat and some resemblingreal coal. Winning

Sometimes lignite or brown coal can be won on a small scale by individuals as is the case with peat. However, usually the lignite seams are covered with so much overburden that the winning has to be left to commercial mining corporations. Lignite can be burned on CO31 grilteS.

300 million

years ago

Fig. 243: Peat, lignite formation is peat and Feat found today may conI up to 300 million

;

50 million

years ago

;

50000

years ago

and coal are created by forests growing in ancient as this is compacted more and more it is converted be only a few thousand years old whereas lignite years.

1 1

times. The starting point for coal into lignite and finally into coal. may be 50 million years old and

Storage

Saggars

Lignite is very friable and is therefore especially likely to break up into small pieces if it is subjected to cycles of wetting and drying. Small fractions and dust cannot burn on the gratesand so the lignite should be stored in a dry place.

Due to the high sulphur content in coal, glazed ware has to be protected in saggars. The consumption of coal when firing ceramic ware III kilns depends on the size of kiln, the firing temperature and the setting type, but it variesrough!y from 0.3-i .5 tons of coal per ton of ware.

2.2.5 Coal

Storage

Coal representsthe last stageof the transformation of vegetable matter and the term coal covers a wide range of heat values and moisture contents. However, all coals have a higher heat value and have less volatile matter than the other solid fuels. Ash content variesfrom l-20% on average.

Coal is more economical to buy in large quantities. So several potters may save money by buying their coal together. Coal does not need to be stored in a shed but should be laid on clean ground. Coal oxidizes slowly wher, exposed to air and this processwill heat up the cod. This heating may 69

cause the coal to ignite by itself if it is piled in large heaps. The preventive rule is not to pile the coal higher than 2 m, smaller piles being lesslikely to ignite than big ones.

garagein Nevada’ was found to contain the following contaminants listed as parts per million (ppmj: iron copper chrome aluminium lead tin silica

2.2.6 Oil products Somecountries havemany different types of oil products while others only a few; therefore, only the most common are mentioned here. Petrol cannot be jrsed for firing kilns because it burns explosLvely.Kerosene is an excellent fuel but is normally more expensive than other oil products though in some countries it is subsidizedby the government. Diesei oil and light fuel oil are rather similar when used for firing. Fuel pil is a very powerful fuel with a heat value of about 30% above good coal. However, it Is also the most expensive fuel and will in many cases not be economical for potters. Wasteoil

Waste oil is as powerful as fuel oil yet cheaper. Waste oil can be obtained from garages, bus and transport companies and railways which are left with a lot of lubrication oil after servicingtheir vehicles.In some countries the lubrication oil is recycled, whereas in others no use is made of it and so it can be obtained for a low price. Some power-generating plants produce large amounts of waste oil when cleaning heavy oil for their diesel engines. This type of waste oil has a high viscosity and is often mixed with water. Waste oil should be screenedbefore use. A 16 or 24 mesh screen is fine enough for drip-plate burners. Conturninan ts

Waste oil contains various contaminants reflecting its life as a lubricating oil in engines, gearboxes, etc. A drain oil from a 70

50 18 7 7 500 5 5

Some people regard burning of waste oil as a health hazard especially because of its lead content. However, the quoted amount of lead equals that in petrol while earthenware clay may contain more than 320 ppm and paper for candy-wrapping may contain as much as 7125 ppm. A potter firing with waste oil will be no less safe than if he had spent the day at the road side. At Bujora Pottery in Tanzania the waste oil gave a pleasan%shine to the unglazed clay. This was probably due to the contaminants of the waste oil. Pollution

Oil and especiallywaste oil are dirty to work with, and a more serious problem is that oil can cause great harm to the drinking water in the whole area if it is allowed to leak into the soil. Therefore, great care must be taken not to spill oil on the ground, and if this does occur, it should be cleaned immediately. If sawdust is always kept close by, it can be used to soak up the oil, and afterwards it can be used for preheating the tireboxes. The ground where screening and filling of the oil tank takes place should be coveredby a layer of cement or bricks in order to prevent the oil leaking into the soil.

’

D. P;lrkv “A Potter’s Oil Firing”, p. 63

Guide to Raw Ghzinp

ilnd

-

-Fig. 2114: Firing

of a tube kiln in Thailand.

An attendant

stokes bamboo

-

from each side.

2.3 Combustion and fireboxes

Carbon and oxygen

It is not possible to learn how to fire a kiln successfully from a bcok. That has to be done by participating in many. many firings as the firemaster’s assistant. However, it is helpful to understand the basic principles involved in kiln firings.

When watching a small fire we notice that the firewood slowly disappears leaving a little ash and that the fire needsplenty of air. But what is behind the magic? Wood and other

2.3.1 Combustion :

It is common knowledge that firewood bilms as doescharcoal. oil, coal and gas.The burning process is called combustion. AU these fuels were originally green plants; firewood and charcoal are made from presentday trees but oil. coal and gashaveoriginated from thick forests uhich covered the earth many hundreds of thousandsof years ago. Ffg. 2-45: Wood (carbon) comhincs gen) and heat iq the result.

wirh

air (oxyD

fuels are mainly made of a material called carbon and the burning process takes place when the carbon combines with the oxygen in the air and forms a new material called carbon dioxide. The process produces a lot of heat. The carbon dioxide escapes and only ash is left. Ash is the part of the fuel which cannot burn.

given off. These gaseswill bum if they come into contact with open flames and this temperature is therefore named the flash point of wood. f:s;;:;‘;;, ‘UL,c;je ga;ses,A$!!-cpu\13;;t open flames only bum at temperatures above 600 “C. This is called the ignition temperature. The temperature of wood flames are 1100 “C while fuel oil has a flame temperature of 2080 ‘C.

Fhh point Solid, liquid, gas

When a piece of wood is heated, initially water and carbon dioxide are given off. Above 280 “C volatile gasesin the wood are Fig. 2-46: Tempcraturcs and flame of wood

1too'c

of

flnsh

point,

ignition

t’-me -leripefciiure

Firewood and coal are solid matter while oil is liquid. However, the burning will only take place when carbon is in the form of gas. All materials exist in three different forms depending on the temperature. The three forms of water are well known (fig. Fig. 247:

Water in its three forms

ICE (x?LID)

600”~

. ky lion impercliwe

72

247). So first we will have to turn our fuel into a gaseous form and then mix it with air. This is the job done in the fireboxes of pottery kilns and it is done differently according to the type of fuel. For the potter, mainly three types of fuel are of interest: firewoocl, coal and oil. 2.3.2 Firewood firebox Firewood bums in two stages.When a new piece of wood is added to the fire, the wood will first give off volatile gaseswhich will burn. (In wood the volatile gasesamount to about 8070 of the total mass, the remainder being in the form of fixed carbon (charcoal).) The flames of a fire are these burning gases and they will often not even touch the firewood. After the volatile gaseshave escaped only charcoal is left and it will bum with gentle blue flames. In the ceramic kiln the two-stage burning takes place in the firebox which enablesus to control the fire. The main problem is to Fig. 249:

Function

of a wood fuebox.

Fig. 248: Wood burns in two stages. The fist, seen to the left, is the burning of the volatile gases. The second, seen to the right, is the burning of the charcoal.

ensure a good strong fire with just the right amount of air needed to combine with the carbon of the fuel. If we let in too little air

The height of ash pit should equal the height above the grate.

some of the volatile carbon gaswill go out of the chimney unburned which can be seenas black smoke. That means wasted firewood. If we let in too much air this excessair will cool the kiln. That too is a waste. fiimary/secondazy air

In fig. 249 air enters at the bottom of the firebox, passes over the embers and goes through the grate. Reaching the firewood it helps to burn the carbon gas being released rapidly due to the high temperature inside the firebox. Most of this air, primar? czir. is used to bum the charcoal and often there will be too little air left for the volatile gasesreleasedfrom the tirewood. Secondary air entering above the grate ensurescomplete combustion for these volatile gases.By thus dividing the air inlet less air is needed and thereby lesscooling of the kiln takes place. The volatile gasesrepresentup to 30% of the heat value of the firewood. In casesufficient primary air passesthe fuel the combustion will be complete, but it would mean an excessof air being 50%100%of the air used for combustion. This excessis reduced to 3050% when secondary air completes the combustion. (hre The wood is spreadout evenlyon the grate so that air has easy accessto it. For firewood the distance between the grates shou!d be 15.--JO cm so that the wood will fall mto the ash pit as soon as it is nearly burned out. Otherwise it will block the accessof primary air. The grate can be made of iron bars but they will soon wear out and grates made of fireclay bars (fig. J-50) are more durable. The ash pit should be as big as or bigger than the spaceabove the grate becausea thick layer of embers is needed to preheat the primary air. 74

Fig. Z-50: Fireclay

bars made

as long solid

fire-

bricks

A mousehole letting air into the bottom of the ash pit can regulate the thickness of the embers. The grate for firewood should be about 15-,215% of the floor area of the kiln chamber, the 15% sufficient for firings up to 1100 “C and the 25% for 1300 “C and above. Firirzg techtzique

Firing is started in the ash pit with big pieces of firewood so that firing begins slowly and it also helps in building up a good layer of embers. Later the firewood is placed on the grate and the secondary air inlet is opened. A properly designed kiln should be easy to take up to about 1000 “C but in order to save fuel care should still be taken to control the intet of air and keep a steady stok. ing going. From 1100 “C to 1250 “C the kiln needs full attention. After stoking flameswill come out of the blow-holes on top of the kiln chamber and the atmosphere inside the kiln chamber will be cloudy. The stoking will cause the temperature to fall and the kiln will be in strong reduction (p. 116). While the wood burns the temperature will rise and the atmosphere inside will become clearer. As soon as the inside is clear, stoke again! This technique produces an oxidizing firing. Reducing firing is done by stoking as soon as the blowhole names have gone. Another point is to keep the grate covered with a thin layer of firewood all the tipe. That way air

Fia. 2-51: Iron arates will last lonrter if they can be removed Kin Book” f&ire wood kiln, p. l?8).

is not rushing through the open spaceon the fire grate. This would cool the kiln; only ten minutes’ neglect might cost an hour’s extra firing. Near the end of the firing thinly split firewood is used. This burns very fast and stoking will need to be done almost continuously by throwing in pieces wherever wood has burned out. However, the last firewood split should have burned out before a new one is thrown on top of it, otherwise the firebox and the ash pit will become choked. Stoking is done through a small hole not allowing in excessair.

after

firing

has been finished

(F. Olsen “The

way round (fig. 2-52). The firewood is fed from the top and the box over the hob can be filled up so that the firebox is kind of self-feeding.

Fig. 2-52: Hob-tirebox

Hub firebox

Conventional fireboxes have the primary air supply under the grate and the secondary over it. The hob firebox works the other

secondary air ash

75

steps -where the fuel is burning (fig. 2-54). This system needs constant attention to ensure proper flow of the fuel evenly over the whole grate area. Otherwise areas without enough fuel will bum through and let in cold air. The system requires a rather big grate area compared to kiln size but can be used for smaller kilns fired up to 1000 “C. (A grate measuring 40 x 100 cm fired a 1 m’ kiln to 1100 “C with rice husks in eight hours consuming 650 kg husks.) Fig. 2-53: Stoking

a bob firebos

2.3.3 Sawdust firebox

Sawdust, rice husks and other agricultural waste materials need special firing systems. The problem is that this type of fuel is very bulky and if used in a conventional wood firebox it would block the grate and only bum slowly on the surface. One solution is to let the fuel fall onto the top of a steep cast-iron grate provided with a lot of small Fig. 2-54: Grate for sawdust. The grate is set at an inclination of 50”. The sawdust is fed at top and should trickle down the grate.

Sawdust injection

In this system sawdust is sucked into a centrifugal blower via a pipe system and sawdust mixed with air is then blown into a conventional firebox. The firing is started with ordinary firewood in order to slowly heat the kiln. After smoking is over and when there is plenty of coal in the firebox the blower is started. In the beginning the firing uses only a little sawdust and firewood will still be needed to ignite the sawdust. When the firebox bricks are glowing red firewood stoking is sropped and the flow of sawdust is gradually increased.A 1.7 m3 kiln is quoted to use 3 m3 sawdust to fire to 1300 ‘C in 11 hours’. For this kiln a 23 cm straight blade blower powered by a 0.3 HP electromotor running at 3400 rpm is used. The sawdust is fed to the suction pipe through a hopper (fig. 2-56) with an auger in the bottom. The sawdust has to be very dry, otherwise the firing will slow down and the fire may even be extinguished. in areaswith no power supply the blower can be driven by a combustion engine and the auger in the hopper can either be connected to the engine by a v-belt or be driven manually ’

76

The sawdust system was developed by L.W. Ba“Sawdust Injection Firing” Ceramics ker, Monthly, September 1977, p. 45-47. Later Steven Howell, Johnson State College, Vermont, U.S.A., developed it further and constructed this kiln.

Fig. 2-55: Sawdust

The sawdust bums very fast almost like liquid fuels. The asheswill not remain in the firebox but will be blown throughout the kiln. Some will settle on the walls and saggars and form a glaze and the rest will leave by the chimney. Firings to above 1250 “C may be done in open settings because the Fig. 3-56: Sawdust the sawdust Intake.

is fed to the suction

injection

system

ash will melt together with the glaze. Below 1250 “C the ash would produce a rough layer on the glazed ware. A hole in the bottom of the chimney will help to provide air for burning up unburned sawdust. The sawdust burning produces a lot of sparkswhich may start a fire.

pipe by a hopper.

The speed of the auger can be used to regulate

Sawdust burner

In fig. 2-58 a modification of the injection system is shown. The sawdust is fed into the blower pipe in front of the blower outlet. This system is simpler but needs constant attention to ensure that sawdust does not clog the outlet from sawdust funnel to blower pipe. Rice husks

The above system has only been tested with sawdust but may also work with other agricultural waste products. Rice husks are rather similar to sawdust except that they have a slightly lower heating value and leave much more ash. The ash has a high silica content which makes it unsuitable for open setting glaze firings. Straw

Fig. 2-57: The sawdust dried before it is used. Fig. 2-58: Sawdust burner dust in front of blower

should with

‘UC screened the intake

and

of SJW-

Straw and other agricultural waste materials can also be burned with the injection system. However, the straw has to be cut into small pieces. If the straw is dry that can be done in a hammer mill witt a coarsesieve. 2.3.4 Cod fireboxes

Coal needs other types of fireboxes compared to wood mainly becausecoal has much less volatile matter and thus resemblesthe charcoal left after the volatile gasesin wood have burned away. Fireboxes for coal-fired kilns are normally of the samesize regardless of the size of the kiln. So bigger kilns simply havemore fireboxes. Grates

The grates are made of iron bars with 2.5-4 cm space in between. The bars are exposed to intense heat from the white-hot coals 78

IL. _ . .__

~..F&#.

-.-.

-1

Fig. 240: Typical grate bars for coal. The thickencd parts adjust the open space between the bars.

Fig. 2-59: Coal-fired down-draught fireboxes inside the wall. Kanagur Institute, India.

kiln having its Village Pottery

and wear out quickly. The cost of renewing the grate bars is a big drawback of coal firing. A water container placed in the ash pit will cool the bars. The resulting steamwill dissociate into ions when passing the burning coal. This action cools the temperature of the burning coal without a correspondingloss of energy. At the same time the flames will

become longer and the coal is less likely to clinker. The life of the iron bars will be much prolonged if they are designedto be removed as soon as the firing is stopped. Cast-iron bars are superior to mild steel bars. Flu tf inclined ,gmles

Hat grates are mostly used for slow firings up to 1250 “C mainly in an oxidizing atmosphere. Inclined grates are used for porcelain and faster firings. (Inclination is usually 1525” but there seemsto be no fixed rule, e.g. lignite should be fired on inclined grates in-

Fig. 2-62: Coal kiln. Secondary the grate bars.

80

firebox similar air is regulated

to the ones seen in fig. 2-59. The fuebox is within the outer wall of the by opening of the stoking shutter and by placement of bricks just above

stead of flat ones.) Types with steep inclination are called semi-gasproducers because they are fmd with a thick bed of coal which produces a lot of half-burned carbon gas. This gas is fully burned by an inlet of secondary air above the grate as in a firewood firing or inside the kiln in caselong flames are desired.

Reheated air

Semigcrs producer

Stoking

A semi-gasproducer is shown in fig. 2-63. The inclination of the grate is SO” and stoking is simply done by filling coal until the grate is covered with a coal bed of the desired depth. At full fling the whole stoking channel can be kept full of coal which will slide down by itself. The problem with this type of grate is to fire at a slow rate. That can be overcome by covering the upper part of the grate with a clay slab during the initial slow rising of the temperature. As more intense fue is needed the slab can be drawn out.

Primary air enters under the grate and if the coal bed is thicker than 10 cm, secondary air is needed too for complete combustion. There are two basic stoking techniques: (1) Frequent stokings are made to ensure that there is an even layer of coal all over the grate and that no place is burned through resulting in a rush of cold air entering the kiln. (2) Stokings are made by first pushing the burned coal to the back of the grate and then filling fresh coal in front. The first method requires more experience and more frequent stokings whilst the latter

Channels for secondary air are built into both sides of the firebox so that when the secondary air enters above the coal bed it is preheated (fig. 264). This will ensure a better combustion of the volatile gas, thereby adding to a better fuel economy.

Fig. 264: Channels in the walls of the firebox preheat the secondary air.

81

tends to be lesseconomi&l becauseit allows too much cold air to rush through the grate during stoking. Every now and then clinkers have to be cleared from between the bars with the help of a bent iron rod, which is inserted from under the grate. Alternrite stoking

Each tune stoking is done the temperature will drop as the fresh coal is heated and it will then gradually rise again. It is therefore better to stoke the fireboxes alternately at an even interval, i.e. say the kiln has four fireboxes and each needs stoking every hour then stoking should be done to one firebox in turn every 15 minutes instead of all four once every hour. The interval between stoking is judged by looking at the smoke from the chimney and at the coal bed on the grate. It dependson the type of grate and firing technique. If stoking technique (2) is used stoking is done every 1-l ‘I$ hours up to 900 “C, then every 45 minutes to 1 hour up to 1200 “C and finally every 30 minutes. The most efficient combustion takes place when the burning rate is about 95-145 kg per 1 m2 grate area per hour (Singer p. 908). The Khurja down-draught kiln burns on average85 kg/m2 per hour. Firebox size

The grate area of each firebox is within 0.30.5 m’. The length is normally 80-90 cm. The total gmte area of ail fireboxes should fall between 12% and 25% of the floor area of the kiln chamber’. 12-1576 would be sufficient in most cases,while 25% would be for fast firing and high temperature porcelam kilns. The top of the firebox arch should be around 80 cm above the grate. The lower t

82

F. Singer, “Indwtrial Ceramics”. p. 91 1, quotes: grate area in m2 chould be 10 ‘Z, of kdn chamber volume in m3.

part of the grate should be at least 50 cm above the floor of the ash pit. Firebox hca tim

The fireboxes should be spaced evenly around the kiln and the firebox may fit within the outer wail due to its small size. The closer to the kiln chamber the better and in the Khurja kiln (p. 51) the bagwall is made as a part of the inner wall, thus saving setting space. The number of fireboxes for a particular kiln is found by dividing the grate area of one firebox into the total desired grate area. 2.3.5 Oil drip firing A simple and reliable drip firing system for oil can be made very cheaply. Oil is fed by gravity to a drip-plate burner and the air is supplied by t,he natural draught of the chimney. Forced air oil-burner systemsare harder to construct and descriptions of suchsystems can be found in techmcal books (see biblio&rapb). As for aU other firing systemsthe important thing is to change the fuel into its gaseous form so that it will ignite. Fig. 2-65 : Firebox for oil drip firing. The drip-plate burner is seen in front of the firebox. Pipes for oil and water arc placed above the firebox.

Water and oil

Ccrbort clinker

ignition can be aided by adding water to the oil in the following manner:

Besideshelping to atomize the oil the water also reducesthe carbon clinker, which otherwise would build up on the iron plates during firing. The water works in the sameway as for coal firing (p. 79) C + Hz 0 = CO + M2. This action cools the plates thus reducing corrosion but the energy is given back again when the carbon oxide and hydrogen burn. The amount of water is judged by watching the flame. It is normally about one part water to five parts oil. *

a valve above the firebox the oil drips down onto a straw, which is fixed to another valve, from where a thin squirt of water runs along this straw (fig. 2-66). The straw breaks the surface tension of the water making many small drops which mix more easily with the oil. This mixture drips onto a set of three iron plates placed inside the firebox. In the initial stagesof the firing the iron plates must be kept hot by a small fire. Hitting the hot plates the water will explosively turn into steam. This action will pulverize the oil into a mist which easily vaporizes and then bums. The system also works without water, but the energy spent on heating the water is negligible compared to the improved combustion of the oil. From

E:ip. 2-66: Chip-plate

burner

Sumer p&es

The iron plates can be made from any type of scrap iron, but the plates should not be too thin otherwise they will wear out fast. The plates are either welded onto a frame as shown (fig. 2-66) or they are placed in

grooves in the brickwork of the firebox. The size of the plates is not crucial and the slope depends on the viscosity of the oil; a plate size of 10x20 cm and a slope angle of 15” are good starting points for experimentation. A gradually decreasingslope ensuresthat the oil bums on all plates and a raised edge will guide the oil flow onto the next plate. The drip-plate burner can easily be installed in fireboxes of other fuels. However, ample space (at least 0.6 m) should be allowed in front of the burner because the oil flames are very fierce. The capacity of drip-plate burners equals that of fireboxes for wood and coal. However, if the kiln is intended to burn ail only, more drip-plate burners could be installed in order to have a more even heat in the kiln chamber.

sity and will have to be heated to ensure a proper flow in the pipes. Waste oil often contains water and a heating system can be combined with de-watering. Two oil drums, welded together to form one long drum, are raised above a small firebox. Around the drum a chimney is made with an inside flue spiralling around the drum to the top. An outlet for water is made in the bottom of the drum and an outlet for oil is positioned about 0.5 m above the bottom. Oil is pumped or ftied into the drum through a sieve at the top. As water is heavier than oil the water will settle at the bottom of the drum and is tapped off now and then. Only a small fire is needed to keep the oil warm. The level of the oil should be at least 1.5 m above the taps at the burners.

01) tmk

Firing

The oil flows to the burners by gravity. Heavy fuel oil and waste oil havehigh visco-

A small wood fire is made in front of the burner plates. If it is a biscuit firing, smoking should be finished before starting oil firing as it will raise the temperature too fast. After about two hours the burner plates will he hot enough to start the oil firing, but the preheating fire should be kept going until the firebox is hot. Without a preheating fire the oil firing will produce black smoke during the initial stages of firing the kiln. In the beginning when only a little oil is dripping the tire will take place on the upper plate. Later, the oil will flow to all the plates and produce an intense white flame.

Fig. 2-67: Oil Unk for separation of water and heating of the fuel oil. In fw. 2-35 a photograph of such an oil tmk is shown.

Fig. 2-68: Preheating

84

of burner

plates

Take care that all the oil dripping onto the plates is ignited and that a pool of oil does not form in the bottom of the flrebox. This could cause an explosiveburning which may even blow out the fire. A mouseholeending in front of the burner will collect the excess oil and by watching the outside end of the mousehole (fig. 2-66) it is easy to discover excess oil flow. The mousehole works as an emergency reservoir and when the oil flow has been adjusted the excess oil harmlessly bums from the mousehole opening inside the firebox. Additional jicel

In order to save oil the firing up to say 1100 “C can be carried out with cheaperfuels Fig. 2-69: Small pressure burner

with a pressurized

e.g. firewood. The last stagesof the firing up to say 1250 “C normally are the most difficult when tiring with firewood. By changing to the powerful fuel oil, the last few hundred centigradesare easily rcacheS..

2.3.6 Pressure burner system

This burner system is based on the same principle as the kerosene pressurestove, only expanded greatly in size(fig. 2-69). The burner is a double-walled cylinder of rolled steel, welded together and fitted with an orifice system. It works with kerosene, diesel oil and light fuel oil.

fuel tank. The pressure is obtained

with II bicycle

pump.

Large burner

Function principle

For firing medium to large kilns it has been The kerosene or oil is fed to the bottom of found that a burner with an inner diameter the double-walled chamber either by gravity’ of 18 cm, 35 cm long and with 9x1.5 mm or from a pressuretank. Initially the burner orifices is sufficient to heat 2-3 m3 of kiln is heated by placing an oil-soaked rag or sawup to 1000 “C. For this size of burner fuel dust inside the cylinder. The heat will vacan be gravity-fed from a minimum height porize the fuel in the evaporation chamber of 4.5 m, which will be sufficient to counterand after a while the pressureof the oil gas act the back pressurein the burner. wiU expel the vapours through the orifices (1.5 mm holes) at the rear of the burner. ’ Small burner The oil gas is ignited by the burning rag and the burner is now operating. The flame of Small kilns can be fired with a version of the -the gas from the orifices will heat up the burner that has an inner diameter of 4 cm, evaporation chamber and the fuel valve can length of 30 cm and a single 1.5 mm orifice. slowly be opened fully. The rate of firing is This sizewill be suitable for kilns up to 1 m3 controlled by the valve at the oil pipe. (1000 “C). More burners can be added for each additionaScubic meter of kiln volume. Rack pressure Because of greater back pressure generated in these small burners a pressurized fuel The oil has to be under a certain pressureto tank must be used. Since a 1 m3 kiln can be counteract the back pressure generated infired to 1000 “C using’approxhnately 25 1 side the evaporation chamber. Otherwise the kerosene, a 50 1 tank pressurized with a vaporized oil gas will escapethrough the oil bicycle pump to about atmosphere3 will do. pipe instead of the orifices. The oil pipe is This burner can be scaleddown by changing fitted to slope downward from the burner the 1.5 mm orifice with a 1 mm orifice. to prevent gas bubbles from entering and thereby blocking the oil pipe. Chimney and firebox

Fig. 2-70: Large pressure burner jam nut and g copper washer I I

2,5 cm

: 18cm , kc

4

i

;:;orifices

-lb 35 cm

3 mm roiled

steel

side view

view from

tirebox

314 inch oil pipe with valve

Because the burner produces a flame under pressure,a large chimney is not required. Air for combustion is drawn into the burner by the venturi effect of the pressurizedfuel gas. A simple up-draught kiln can function without any chimney while a cross-draught or down-draught type will need a Iow chimney to pull the combustion gases properly through the kiln setting. The burner is placed with a gap of 3-5 cm from the firebox inlet in order to let in secondary air. An opening in the kiln wall is sufficient but the flame should be allowed a free space of about 0.5 m in front of the burner. In general, severalsmall burners will produce a more

even temperature compared to one large burner.

The cylindrical chamber should have an airtight lid that will facilitate cleaning out minor depositswith petrol between firings.

Carbonization Steam

However, small pressureburners tend to become blocked by carbon deposits inside the cylindrical chamber, especially if the temperature in the chamber becomes too high, These carbon deposits are very difficult to remove and so it is best to avoid overheating the cylindrical chamber by leaving a sufficient gap between the burner outlet and the firebox opening and by ensuring an additional natural draught of air. Kilns with additional draught, powered by a chimney, show little tendency to cause carbonization problems compared to chimneylesskilns.

.

Several successful firir~gs,~havebeen done with a modified small pressureburner in Nepal. Oil was substituted for water so that steam was generated in the cylindrical chamber and this was forced out under high pressure through a single sr&l orifice. The oil was fed in front of the steam orifice by a brass pipe where it would be vaporized and blown through the burner by the steam. A back pressure valve is needed between the burner and the pressurized water tank. Initial results indicate that fuel consumption equals that of a similar type of oil burner.

Fig. 2-71: 2 m3 down-draught shuttle kiln with four small pressure burners. Exit flue is in the bottom of the shuttle car.

87

2.4 Heat transfer and draught The hot combustion gaseswill, after leaving the fireboxes, passthrough the kiln chamber on their way to the chimney. The more heat the combustion gases tr&lsfer to the ware <while they pass, the more efficient is the firing. If the gasesleaving through the top of the chimney are still very hot this means that a lot of heat or fuel is being lost. The transfer of heat takes place in three different ways: 2.4.1 Transfer of heat through air Convection

Heat is transferred to the kiln walls and to the saggarsor kiln setting when the hot gases from combustion passthrough the kiln. Heat transferred in this manner by circulating air is called convection. Increasing the speed of the air (velocity) will result in the transfer of more heat.

solids is callsd conduction. Heat transferred by conduction will take some time and so the air outside the saggarswill at fmt be hotter than inside where the pots are. This should be kept in mind when fling and is one reason for soaking the kiht at top temperature so that the temperature throughout the kiln will even out. Kiln walls

Heat will also pass through the walls of the kiln and be wasted. The use of insulating. firebricks for the inner wall will reduce this loss. The many small holes in insulating firebricks will reduce the passagewaysfor the conduction of the heat. However, if the holes are too big the air inside the holes will have room to circulate and transfer the heat by convection (see fig. 143, p. 35). The weight of the insulating bricks is less than solid tirebricks and so the fuel that would be needed to heat that weight difference is also saved.

Kiln setting

2.4.3 Transfer of heat by radiation

Just as a river will run fast where it is narrow and more slowly where it widens, air streams act in the sameway. Therofore, a half-filled kiln with a lot of space between the saggars would fire badly. For an efficient firing the kiln should be set with many narrow passagesthrough which the hot. gaseswill pass quickly.

Finally heat can also be transferred by radiation from a glowing surface. The sun transfers its heat to the earth by radiation. The more a surface is glowing the more heat it will transfer to its surroundings. At the end of a firing everything inside the kiln glows white-hot and will radiate a lot of heat. This radiation helps to even the temperature inside the kiln. The hotter parts will glow more and,transfer heat to the cooler spots. A soaking period will give this radiation time to even out the temperature differences. The insulating firebricks have here another advantage over solid firebricks; as less heat escapesthr~& the insulating bricks their surface temperature wui become higher and so they will radiate more heat back to the kiln setting.

2.4.2 Transfer of heat through solids Conduction

As the kiln setting becomes hot by heat transferred by convection this heat will also pass through the saggarwalls and reach the pots inside. This transfer of heat through 88

Fig. 2-72: At red heat the kiln walls will radiate heat back to the kiln setting.

Kilrl wash

Some potters paint the inside of the kiln with a feldspar mixture which will melt and produce a shiny surface.This will add to the reflection and radiation of the kiln wall and will make a considerable difference especially in smaller kilns. 2.4.4 Natural dnugh t

Fig. 2-73: The hot air in the chimney weighs much less than cold air of the samevolume. The balance illustrates this weight difference.

inside the chimney. The maximum weight of gases is pulled through the chimney when the temperature of the gasesis around 300 “C. With higher temperatures more volume of gasesis passingbut it weighs less. The pull should be sufficient to create a good draught through the fireboxes and the kiln chamber.

Chimney Chimney dimensions

One litre of hot air weighs lessthan one litre of cold air. So hot air will rise following the same law of nature that makes a piece of wood ascend when it is immersed :in water. This law is used to produce a draught or pull of air in kilns by the help of a chimney. The column of hot air inside the kiln weighs less than a similar column of outside cooler air and this weight difference wilP produce a pull at the bottom of the chimney. The force of the pull will increasewith increasing height and volume of the chimney and with increasing temperature of the gases

Some general rules exist for the dimensions of a chimney according to the size of the kiln. The following dimensions apply to high temperature firings and less height could be used for low temperature kilns: 3 m of chimney for every 1 m downward pull plus 1 m of chimney for every 3.5 m horizontal pull. The height of chimney for the kiln in fig. .. 1 -.-?.>i; ;.,. ‘+15 3 x 2.2 + --;3.5 = 7.6 tn. 89

cl.5

m -224

Fig. 2-74: Kiln with downward horizontnl pull of 3.5 m

pull of 2.2 m and

The bottom area of the chimney should be approximately 10% of the area of the kiln chamber. Dampers

A slight tapering of the chimney at the top will increase the speed of the air passing through the kiln. However, too strong a pull will cause irregular heating. The pull can be regulated by the use of dampers or by making an opening at the bottom of the chimney through which cold air will be drawn in and causethe pull to slow down. Veluciry

The pull will be slow at the beginning of a firing but when the temperature in the chamber is around 1100 “C the speed(velocity) of gases through the kiln should be 1.2-- 1.5 m per second. This can be checked by throwing an oil-soaked rag into the firebox. The time taken for the black oil smoke to come out of the chimney should be noted. The total distance covered by the gases is 90

C_

a

--

Fig. 2-75: Three different types of dampers. Dampers arc placed between the outlet flue of the kiln and the chimney.

from the firebox up the kiln wall acrossthe arch and down to the outlet flue’ . distance in m The speedof gases= seconds ’ The pull during wood firing is right when flames and smoke come out of the blow holes (a sign of back pressure) right after stoking. If there Is no back pressure, dampers should be closed more to reduce the draught. 1

Ths method Kiln Book”,

i\ quoted

p. 53.

fram

I-‘. Olsen,

“The

2.4.5 Flues

2.5 Kiln constructisn

The openings or channels carrying the gases from the firebox to the kiln chamber (inlet) and from the chamber to the chimney (exit) are called flues. The size of inlet and exit flues should be of equal but generoussize. One litre of air at 20 “C will expand to 4.5 litres when heated to 1250 ‘C and so the cold air entering through the primary and secondary air inlets needs4.5 times larger openings after it has been heated in the firebox. The size of the flues should be slightly bigger than the cross-section of the chimney. Another measuresuggeststhat for each 1 m3 of kiln chamber there should be about 600 cm2 flue area. In any caseit is better to make the flue area too big becauselater when the kiln is finished it is easy to reduce the flue size but difficult to increaseit.

2.5.1 Site of the kiln The site of the kiln should be selected carefully. At some stages of the firing a lot of smoke will develop and sparks from the chimney could cause fires at nearby houses. If possible select a site for your kiln at a safe distance from neighbours. The kiln site should be dry and preferably levelled above the surroundings so that the kiln, its foundation and flue system will not come under water during rainy seasons.Ample space is needed around the kiln for stacking and drawing the ware, for storing saggarsor kiln shelves and for storing fuel. Firewood is especiallybulky (see fig. 2-76, p. 92).

2.4.6 High altitude

2.5.2 Foundation

At high altitudes there is lessoxygerl in the air than at sea level. So kilns built in mountainous regions need to pull more air through the firebox for combustion of the same amount of fuel. Therefore, the height and diameter of chimney and size of flues should be made larger to allow for this extra air. Roughly the chimney and flue dimensions are expanded 1% for each 100 m altitude abovesealevel.

Construction of a kiln resemblesthat of a common house built of bricks. The bricklaying technique only differs a little and ordinary skilled masons will easily adapt themselves to the task. For larger kilns it is recommended to consult local building specialists (engineers, architects, masons) with experlence in major constructions, particularly for assessingthe size of proper foundations according to the type of soil and climate of the kiln site. In particular, foundations for chimneys above about six metres need a good foundation to ensure the chimney will not lean. Apart from the chimney only the supporting walls need foundations. The foundation should be exactly levelled by using a spirit-level. Levelling over larger distances can be done with a hose filed with water (fig. 2-77). A clear plastic hose is fitted to each end of the hose. So the level can be easily observed. Take care that no air bubbles are trapped inside the hose.

Example:

A kiln designed for sealevel with a 6 m high chimney of 0.5 m diameter is to be constructed at an altitude of 1400 m. New height of chimney = 6 + 6 x 14% m = 6.64 m New diameter of chimney = 0.5 to.5 x 14%m = 0.57 m. The added inside volume is nearly 50% in this case.

91

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rather to provide a level bed for the bricks by filling up the space between irregularly shapedbricks (fig. 2-80).

2.5.3 Masonry Mortar

The mortar (p. 38) should be mixed with water a day or two before use. Avoid any lumps and big pieces of grog. The consistency of the mortar should be soft, nearly sliplike. Some prefer to soak the firebricks in water before laying them. The joints are the weakest part of the structure and they should be as thin as possible. The mortar is not meant to stick the bricks together but Fig. 2-80: Mortar is used for filling tween irro~ularly shaped bricks.

the spaces be-

Laying

The mortar is laid out with a trowel but only for one or two bricks at a time. Each brick is tapped into position with the trowel or hammer until it is in line (fig. 2-81). Immediately check its position with the spirit-level both vertically and horizontally and readjust if necessaryby tapping lightly. In case adjustment is done later the brick and mortar should be removed and fresh soft mortar applied. The joints should also seal the kiln chamber. Therefore, be sure that the joints are completely filled with mortar. cutting

Cutting of firebricks is done with the claw of a brick hammer by tapping the brick all Fig. 2-82: Cutting Fig. 2-81: the wall.

Each brick

should

level vertically

with

of firebricks

around along the line of the cut. After about two rounds of tapping the brick is given a sharp blow on the edge while resting in the hand or on a bed of sand. Some people prefer to use a brick chisel for the final blow. Insulating firebricks can also be cut by a saw though the saw will afterwards only be suitable for cutting bricks. Cutting by saw could be reservedfor specially shapedbricks such as skewbacksand arch bricks.

Fig. 2-84 : Stretcher

big. 2-85: One header courses

course

stretcher

course

for

each three

23.4 FIoor and walls Normally the floor is laid last, but flue &annels passing under the walls will need to be made at the same time as the foundations. The basic rule for bricklaying is that joints should never be in line but always be bridged by the next brick course. There are two basic bricklaying patterns: header course and stretcher course. Header course

Header courses are laid across the wall, thereby only exposing the smallest face of the firebricks to the high temperature inside the kiln chamber. For our self-made firebricks, often possessinglimited refractoriness,this is an advantage. Fig. 2-83: Header course

Fig. 2-86: Stretcher kihi

courses in a Chinese-type

tube

J tretcher course

Stretcher courses are laid along the wall, but for straight walls stretcher coursesalone will only be strong enough for unsupported walls lessone metre’s height (bagwalls). One stretcher course for each 3-4 header courses is suitable for 23 cq walls. A 23 cm wall is safe up to about 2 m height and a 34 cm wall is safeup to about 4 m.

2.5.5 Curved wails

Round kiltls

Fig.2-88: Curved walls are found in circular kilns which have proved very durable. A circular inner lining can stand alone because the bricks are wedged together in the same fashion as an arch and will not fatl into the kiln. So a curved wall does not need to be bonded with the outer wall. Instead a gap of about 5 cm can be left between the inner and outer wall. This gap can be filled with ash or a mixture of 70% sawdust and 30% clay (volume). A curved wall is laid in the same manner as a straight wall. Normally only header coursesare used.

Fig. 2-87: Cross-cut

of a circular

kiln wr~ll

The dome

is restingon the outerwall.

Wuil thickness

Circular kilns with diameters up to 2 metres are made with a 10 cm inner lining, 2-3 metres with 15 cm and above 3 metres with 23 cm. The inner lining should preferably not support the dome which instead is made to rest on the outer wall (fig. 2-88). That enables the wall to be replaced while leaving the dome in place and the wall, only carry ing its own weight, can be made from light insulating bricks. The outer, dome-supporting wall should have twice the thickness of the inner lining and is made from ordinary red bricks laid in an ordinary mud/sand mortar. 2.5.6 Arches

insulatingbrick

\ loose filling

red brick

Arches are used to bridge doors, flues and fireboxes and to form roofs for rectangular kiln chambers. Square bricks can be used for laying arches if the joints are filled properly. However, if available. tapered bricks are preferable as they produce a more durable arch. In case firebricks are self-madea number of tapered shapesshould be made for the

9

key brick

Relieving arches

\ centre of arch

A relieving arch is used to remove the load from the tnain arch. Normally it is rarely used. However, the firebox shown in fig. 2.92 benefits from having a relieving arch above, which would carry the load of the kiln wall. A relieving arch also makes it easier to rem place the bricks of the main arch when these wear out. The important feature is the gap between the relieving and the main arch which ensures that no weight is being carried by the main arch. A loose fdler, such as asbestosor a sawdust/clay mixture can be used to fill the gap.

Q. -$. \

Skewbacks

construction of arches. The number of bricks and their degree of tapering can be calculated (see appendix). The main point is that the outer size of the arch bricks is big ger than the inner size so that each brick is prevented from falling in. That means the higher the rise of the arch the stronger it is. Normally a rise of 20 cm for each 100 cm span is reasonablefor roofing kiln chambers. (12.5-X cm rise per 100 cm span is within normal good practice.) However, in fireboxes, especially for oil firing, the firebricks are under severe conditions and a rise nearly half of the span is advisable if the iirebricks are of poor quality. The firebricks will shrink causing the arch to sink and especially the joints are exposed to the fluxing action of ashes. Fig. 2-90: Firebos arch after Ister after firing shrinkage of taken place. The initial high rise arch from collapsing due to firing

The arch is resting on a skewback at both ends. The wetght of the arch is transferred to the walls through the skewbacks. These are made from square bricks cut to the proper angle (fig. 2-91). The skewbacks should be laid very carefully because if they fail the arch will come down. Fig. 2-91: Skewbacks

cut from square bricks

construction. and the firebricks has saved the fireboa shrinkage.

Arch from e

While the arch bricks are being laid, a support frame is needed. This is made of wood (fig.

Fig. 2-92: Relieving

arch

2-93). The frame is raised until its sides are level with the skewbacks. Laying rhe arch (fig. 2-95)

Construction of the arch is started from both sidesworking towards the middle. Each brick should be placed so that it follows the Fig. 2-93: Arch support

frame

circle of the arch by pointing towards the centre of the circle. Extra care is needed to ensure that .the joints are completely filled with mortar. This is done by applying a thin layer of mortar on both surfaces and after the brick is laid it is rubbed back and forth. With a hammer and a piece of wood the brick is given a few taps at the lower end. The bottom of the points should be as thin as possible. The outer part of the joints might be thicker depending on the tapering of the bricks. Thicker joints should have small pieces of broken firebricks forced in from aboveafter the whole arch is laid. Fig. 2-94: Bottom possible.

of the joints

should be DS thin as

97

Fig. 1-95: Laying the m ii

L ten tre

Square brick arch

In case no tapered bricks are at hand ordinary square bricks can be laid as shown (fig. 2-96). but at least the key brick should be tapering and should be forced below the other bricks. The square bricks are laid so that the upper one is resting a bit inside the corner of the lower one in order to prevent it from slipping out. A squarebrick arch will have thick outer joints and these should be filled with broken tirebrick pieces. Bonded arch

As for all other brickwork the joints should, as far as possible, be broken as shown (fig. 2-97). In case one brick should fall out the bond will keep the arch from collapsing. When the key bricks are in place the wooden frame can be removed. 98

Fig. 2-96: Square brick arch

Fig. 2-97: Bonded arch

Domes

Arch spans and thickness

2.5.7

The thickness of the arch depends on the span and rise of the arch, the temperature of firing and the quality of the firebricks. The highes?temperatures are reached at the outlet of the fireboxes and the arch here should. be 23 cm thick. Generally, solid heavy firebrick archesspanninglessthan 1.5 m are laid with 12 cm thickness,up to 4 m spans23 cm thickness and above that 34 cm is used. Insulating firebricks are lighter and thickness above 23 cm is not used for spans even above 5 m’ .

Circular kilns are roofed with a dome. A dome is a more stable structure than an ordinary arch and requires no supporting frame for its cor.struction. The radius and rise of the dome circle are calculated as for arches (see appendix). Domes are normally made with a rise of 20-25 cm per 100 cm span. A stick’ with the length of the radius and thickness of the dome is tied at the centre of the dome circle (see fig. 2-99) in such a way that it can move both around and up and down. Take care that the stick is really pivoting at the centre of the dome and that it will not become displacedduring construction.

t

Norton: “Refractories” p. 702

Fig. 2-98: Construction of 3 dome

99

Laying the dome

Fig. 2-99: Arrangement of dome ruler

Skovback

The skewbacks on top of the circular kiln wall are then laid with the guidance of the stick. The skewback bricks are iaid as headers(fig. 2-100) cut to the prope.rangle. Fig. 2-100: Skewbltcks xc’ laid 3s hcadcrs

The laying of the first course of the dome is started by placing two bricks, also in header position, on the skewback. The joims should be as thin as possible. The stick is laid on top gf each brick while tapping it into line with the stick and the lower edge of zach brick should be in line with the mark on the stick (see fig. 2-98). Each brick will then be pointing towards the centre of tf,e mo.Jeablestick. The stickiness of the mortar wi!i prevent the bricks from slipping and as soon as more bricks are laid they will squeezeeach other into place.The masonstandsirlsideand works around until reaching the starting point (fig. 2-101). The last brick has to be cut so that the circle course of bricks interlocks tightly. A new course of bricks is laid in the same fashion taking; care to overlap the joints of the former c:Jurse. Each round of bricks will lock itself and there is not the same need for broken joints as with ordifist course of dome bricks

Fig. 2-101: Starting the dome of the Rujora kiln. Note the insulating loose layer between the inner fiiebrick lining nnd the outer wall. The bagwrlls proved to be too high and were later cut in half. Fig. 2-102: Only a few coursesare still to be Inid an11C.,l~hbrick has to be cut to size.

nary arches. As the circle of brick courses becomes smaller the bricks shnuid be cut slightly at the edges on the inner side in order to give better lock. When the mortar is dry it is safe to walk on the dome and from the top all the joints should be gone over to ensure they are completely filled with mortar. Normally a vent hole is left in the centre of the dome. Domes can be constructed in similar ways for covering clay cellars or underground tanks for water. In that case a lime mortar is suffcient. Fig. Z-103: C’atenxy arch under construction. Singlsi, Tmza~u~. 2.5.8 Catenary

arch

2.5.9 Arch construction without support

The shape of a catenary arch is found by hanging a chain or heavy rope between the ends of the span so that the rope touches the top point of the required arch. The curve is copied onto a wooden board which is used to form a wooden frame. An arch with this shape is self-supporting and so steelwork is not needed. A catenary arch can be laid with squarebricks.

Fig. 2-103: A chain forms the shape of :I catenary arch. .__.~.... P4

An alternative method of arch construction which does not require a wooden support is suitable for catenary arches or archeswith a high rise like barrel vaults. In this method, the face of the arch is sloped back from the vertical and the vault develops from back to front by first laying a complete arch, one brick thick. then adding one full arch at a time. The initial slope of the arch is built up against the end wall of the kiln as shown in fig. Z-105. Mortar

The mortar should be plastic so that Its stickiness will prevent bricks from falling until the key brick is set. A simple bent wood or bamboo guide, made to the inside curve of the arch, keeps the curve uniform. Brick shtrpe

Ordinary square bricks can be used for this construction method. However. specially shaped bricks, which ant thinner but wider than standard, will make construction easier. Bricks like this are used for tiie large sloneware kiln shown in fig. Z-107.

Fig. 2-105: Construction uf ;t catenary arch without support. Beginning of construction. Nepal.

Fig. 2-l 06 : Each row of arch bricks is completed at a time. Nepal. Fig. 2.107: Bamboo guide keepsthe curve uniform. Specially shaped bricks are used.

mal expansion and therefore expansion joints can be omitted. In conclusion, expansion joints are only needed in big square kilns, Lid with hard-fired bricks and supported by steelwork.

Fig. 2-108: Expansion jomts in a kiln wall. Side elevation. Fig. 2-109: The same expansion joints as in f@. 2-108 seen from the top of the wall

2.5.10 Expansion joints

The firebricks might expand OS-l% each time the kiln is fired and they will shrink again while cooling. In small kilns (1 m3) this is of no concern but in bigger kilns the expansion might cause the wall to crack and bulge if the construction is made too tight. Joints, ‘/2 cm thick, are made without mortar for each 1 m length of wall. Such expansion joints are made starting from the corners in numbers according to the length of the watt. Steelwork

However, the expansionjoints are only needed for kilns firmly supported by steelwork. Free-standing kilns without steelwork will just expand as a whole and fall back again and circular kilns with an insulating layer witt need no expansionjoints. If the kilns are laid with self-madefirebricks these will often shrink additionally during the first firings of the new kiln. Only if the firebricks have been fired at a much higher temperature will no more shrinkage occur. This additional shrinkage makes room for the normal ther-

2.5.11 In.cdation

During firing heat goesthrough the kiln wall and is lost. Heat goes through solid matter (conduction) but is stopped by air. Good heat insulation means as much air as possible but the air should be in small .pockets, otherwise the air will rotate and thereby transfer the heat (convection). The most practical sohition is an insulating firebrick wall backed up by ordinary bricks. In some cases a gap of about 5 cm can be left between the inner and outer wall. This gap can be tilled with some very light loose mateliSltS.

Loose layer

This can be a mixture of (by volume) 30% plastic clay and 70% sawdust. The sawdust will slowly bum out leaving insulating airpockets. Ash is an even better insulator, but unless the ash has been calcined it will lose much of its volume after a few firings. A simple solution is to leavea few loose bricks in the top of the wall to allow for the refiling of ash. If a loose insulation is used spyholes and vent holes should be lined so that the insulation does not fill the holes. A similar loose layer can be laid on top of arches and a layer of flat tiles may be used to cover the insulation for protection.

2.5.12 Maint.enunceof kilns

Nearly all kilns show cracks after the first few firings and it does not mean that the

Fig. 2-l 10: Look out for hrlcks falling in and refill mortar in loose joints. kiln is about to collapse. However. after each

firing the condition of arches and dome should be icspected carefully for bricks beginning to sink in or for joints which have become loose or fallen out. These defects should be mended immediately to prevent the arch from collapsing. Flue channels, dampers and bagwalls should likewise be checked. It is an unnecessarywaste of time and energy to stop a firing halfway through because a damper is blocking the draught or a bagwall has collapsed. The flue channels should be cleaned regularly. Fig. 2-1 12: Drying pots in the sun

Fig. 2-l 11: Collapsed two-chnmber kiln

2.6 Loading and setting of the kiln cry pm

When the raw pots are dry they are ready for firing. This can be checked by holding the pot to one’s cheek; if any coolnessis felt then it is not sufficiently dry to be fired safely.

The pots can be left in the sun for a day to ensure they are completely dry. Another method is to light a small fire in an empty kiln for half a day after which the pots are loaded and kept in the warm kiln overnight The gentle heat remaining in the kiln walls will dry the pots and next morning the firing can start. Biscuit/glaze firing

Some workshops glaze the raw pots and fire them only once while others prefer to fire the green pots without glaze (biscuit firing), then glaze the pots qnd fire them once more (glaze firing).

inside each other. However, around 700 “C clay expands and then later it shrinks again. Therefore rhe pots should not be set tightly tiside each other and a gap of at least 5 cm should be left between the pots and the top of the kiln. Cups, bowls and pitchers should be placed rim to rim and base to base.Tiles, saucers and other flatware will often show less breakage if placed vertically againsteach other. Fig. 2-l 14: Stacking like this may curse breakage.

2.6.1 Loading biscuit firing

Before loading a kiln it is preferable to have 1 ‘/z times the ware neededto fill the kill?. A wide selection of sizes and shapesmakes ii. easier to fully utilize the kiln space. The sameidea applies to glaze firings.

Fig. 2-l 15: Correct way

of stacking

Stacking

CJnglazedware can be stacked on top of and f?g. 2-113: Pots stacked for biscuit firing

Fig. 2-116: Flatware is better stacked on edge.

106

-

Height .of settittg

\

The height of the stacked pots depends on the quality of the clay and the types of pots. The green strength of highly plastic clays is much greater than sandy clays and thin green pots will break before thick-walled ones. In case the pots cannot be stacked from bottom to top without breaking, the pots can be set in smaller stacks supported by kiln shelvesresting on props (fig. 2-l 13). The same persons should always both load and draw the pots from the kiln so that they can learn from their mistakes. Lust check

While the pots are being placed in the kiln they should be given a last check. It is a waste to fire broken pieces and at this stage it may still be possible to correct a minor flaw in a pot before firing. This checking is needed to improve the quality and correct mistakes done during earlier production of the pots.

placed separately either on kiln slabs or in saggars. Provided the glazed pots are not harmed by direct exposure to combustion gases and ashes,kiln shelvesare the best solution. For the same space a kiln setting with slabs carries more pots compared to saggars,which are also much heavier. The ratio of kiln furniture to ware is about 4 : I for saggars but only 2 : I for slabs. Sometimes saggars are set as a bagwall (fig. Z-30) behind which kiln shelvesare placed. Kiln wash

Before setting, glaze droplets from previous glaze firings should be chipped off the slabs or saggarsand these should then be given a refractory kiln wash. A suitable wash can be made from a powder of silica sand or quartz mixed with water and *gumarabic or another due- Another suitable kiln wash can be prepared with I/* kaolin and 1/2 silica powder mixed with water. Alumina, zirconium silicate and silimanite are excellent for high temperatures, though expensiveand often not available.

2.6.2 Loading glaze firing Slabs or saggars?

A glazed pot will stick to anything it touches during firing so that pots will have to be Fig. 2-117: Open setting of slabs combined with saggars

Fig. 2-118: Stacking wxth thimbles

The kiln wash will prevent pots from sticking to the kiln furniture, which will also be less likely to stick to each other. Glazesaccidentally running off the pots will also be easier to chip off after the firing. The wash can be painted on with an ordinary paint brush.

3. Small hand-made clay balls of ‘/Z kaolin and ‘/? silica powder with the addition of a glue (a cheap flour of cassava,maize or the like works well) can be stuck onto the bottom of the pots before they are placed in saggarsor on shelves.The balls are madejust before setting is done (fig. 2-119).

Lids

Eurthenware setting

Pots with lids such as teapots and jars should be fired with the lid in place so that the lid and the pot will Et together after firing and the colours will be the same.This is especially important for high temperature firings. The faces of contact on the lid and the pot should be free of glaze and should be painted with a silica powder mixed with glue.

Pots made from clay which does not soften or warp during firing can be supported on only a few points. Stilts and spurs are used for setting pots with glazed bottoms and they can also be used for placing glazed pots inside each other (fig. 2-120). Flatware such assaucers,dinner platesor tiles can be placed vertically and supported at the top with thimbles (fig. 2-122). These can also be used for stacking bowls or plates horizontally in which case a cover for supporting the stack of thimbles is helpful (see page 29 f.). Bowls and plates could also be placed rim to rim and base to base if their

Sticking

The simplest way of placing glazed ware in the kiln is to remove any glaze from the foot of the pots and set the pots directly onto the shelf or saggar. However, at high temperature firings, especially when stoneware clays are used, the pots tend to stick to the kiln furniture. To avoid sticking one of the following methods should be used: 1. The pots can be set in sand, but care should be taken during setting to avoid knocking sand into the glazed ware on the shelf below. 2. A silica powder wash can be painted onto the feet of the pots. Fig. 2-l 19: Freshly roiled balls are stuck to the pot and It is then set in the kiln.

108

Fig. 2-120: Setting with stilts

.

rims and bottoms are left unglazed. if bowls are made to accurate measure and with a thick rim, they can also bc stacked hanging inside each other (fig. 2-123). ‘Kissirlg”

Fig. 2-121: Spurs resting on thr of the plates

Uli~litZ.Cd

bottom

Fig. 2-122: L’hlmhles used fur setting tiles vcrti-

The glazed pots should be placed carefully 3-5 mm apart. This will prevent them from “kissing” each other when the glaze and clay expand during iiring.

Fig. 2-124: Glazed pots should he placed 3 5 mm ;tp;lrt to prevent them from “kiwng”.

cdly m s~gpurs

FIN. 2-123: Bowls only glazed inside can be stacked ~~wginginside eitch other.

Cold spots

All kilns will have some cold spots, where the correct maturing glaze temperature is not reached. To gain maximum use of the kiln space and to avoid second-rate.underfired ware being produced in these spots, a lower melting point glaze should be applied to pots which are to be stacked in these areas of the kiln. A good understanding of the kiln and careful stacking will ensure maximum results from each firing.

Saggarsare normally filled with glazed ware outside the kiln and stacked on t.op of each 109

Fig. 2-125: Cups are set in suggi1r.s outside the kiln.

other inside. Before pIacing the saggar its outside base should be dusted to prevent any dust settling on the glazed ware in the lower saggar. Each stack of saggars, called a bung, should be set straight and not rock. The bungs are set a bit apart to allow a proper draught through the setting and if the bungs are tall a few lumps of clay are squeezedinto the gap between the bungs so that they form an interlocking bridge support for each other. In casethe firing temperature is close to the softening point of the saggarsspecial fireclay bars could be set between the bungs and the kiln wall for additional support (fig. 2- 126). A wad of ciay laid on top of the caggarrim (fig. 2-127) will seal the sapparand provide a safer setting if the saggarrims and bottorns are not even. New green saggarsshould only be used for the upper 3-5 layers of saggars. 110

Fig. 2-126: Fireclay bar supports a bung of saggars.

on one side and large pots on the other side of the kiln chamber could result in uneven firing temperatures. Slabs that saggedin the former firing are placed with +Lheirsag upwards in the next firing.

Fig. 2-127: Wadsof clay are laid on top of the saggar rim.

Kiln slabs

The structure of kiln slabs and supporting props or firebricks is nornnffly rebuilt with each new setting of ware. Each slab should be supported at three points only because it is unlikely to rest evenly on a four-point support and the slab would then be under tension, which could cause it to break. The kiln setting is placed layer by layer and it should be done evenly so that dense layers of (for example) cups are mixed with more open layers of larger pots. Having all cups Fig. 2-128: Slabs should be supported at three points only ii possible.

The brickwork of the kiln door should have the same insulating quality as the wall of the kiln. Bricks are to be laid in a refractory mortar, which has a high proportion of sand in order to make it easy to break up the door afterwards. Spyholes should be left at the top and bottom of the door, with neatly fitting bricks provided for closing the holes. F:ig. 2-129: Bricking up the kiln door. Note the spyhole Icft at the bottom and that cones and test picccs arc placed in snggarswith their sides knockcd out.

,

2.7 Kiln firing

Firemaster

The firing is the last step in the production of pottery and all of the potter’s previous efforts during production may be either rewarded or ruined in this final process.

At each firing there should be only one person in charge, the firemaster. The firemaster supervisesall work from setting the kiln, firing, cooling until drawing. All major decisions such as when smoking is over or when the firing is finished are taken by the firemaster. A kiln during firing needs constant attention, and even when using a convenient fuel such as oil the firing process must be carefully watched. When a kiln is fired with solid fuels such as coal or wood a steady stoking is needed. A good firemaster listens to the breathing of the firing and checks the conditions in the fireboxes and inside the chamber many times every hour.

Firing mu tine

Au potters feel excitement and anxiety when opening their kiln and inspecting the outcome of the firing. However, it is possible to reduce the anxiety once a successful firing routine has bef=a developed. Each kiln has its own peculiarities and it often takes up to ten firings to break in a new kiln and learn its secrets. This should be done in a systematic way and recorded so that mistakes are not repeated and experience is gained from successes.

Fig. 2-130: Kiln log-book

112

Kiln log-book

Each firing should be recorded in detail in a log-book, so that afterwards it is possible to twacethe reasonsbehind possible misfirings.

The following things should be noted down: - repairs or alterations carried out, - number and type of ware in the kiln, - pattern of setting of saggars,slabs and pots* - condition of fuel (such as wet firewood),

- date and time of lighting fires in the different fireboxes, - smoking time, - start of real firing, - stoking intervals and rise of temperature, - bending of cones or drawing of test pieces, - position of dampersand draught, - condition in fireboxes during firing, - finishing time, - cooling tinre and time of opening spy holes and kiln door, - fuel consumption. While. the ware is being drawn, it should be noted where the different pots were placed in order to get a picture of where the kiln was too hot or too cold. Finally the ware could be rated as first-, second- and thirdclass and the estimated value of the fired pots should be recorded too. After that the firemaster and the firing crew should discuss the outcome of their firing and they should try to pinpoint problems and decide upon how these problems could be solvedat the next firing. Some of the problems may originate from an earlier stagein the pottery production. Only by experience can a successfulfiring routine be establishedand this sort of practical understanding is difficult to gain from books. However, it is hoped that some of the instructions given here will be of use for the firing itself. This chapter dealswith tlie general techniques of operating kilns. Information on how to stoke the fuel and operate the fireboxes is given in the previous chapter: Combustion and Fireboxes.

1

2.7.1 Biscuit firing Smoking

Even if the pots felt dry when they were loaded into the kiln they will still hold some water. Pots are normally dried in the open air, but air always contains some water and during the rainy season the air can become very humid. The air left in the space between the clay particles contains the same amount of water as the air outside. This pore water will expand explosively if it turns to steambefore leaving the pot. Very plastic clay has small clay particles, which will only leave small openings for the pore water to escapethrough. Sand or grog added to such a clay will make big holes through which the water can more easily pass.Therefore, sand and grog will iinprove a clay which tends to crack during drying or smoking. The pore water will only dry out when the pots are heated to .temperatures of 50100 “C inside the kiln. If this heating goes too fast the pore water will turn to steam before it can get out of the pots. The pressure of the steam will causethe pot to crack or evenexplode (fig..2-131). Therefore, a long period of very slow heating is needed until all of the pots are completely dry. This period is called smoking and it should count for approximate one third of total firing time. That means 3-12 hours or even more depending on the nature of clay, types of ware and size of kiln, The first firing of a new kiln could mean smoking for days to enable the kiln itself to completely dry out. Vent holes

During smoking a very gentle fire is kept in a few or only one firebox and in the beginning this fire may even be placed outside the 113

pore water d)

Fig. 2-131: Clay shown in four stages. The clay crystals are made 100 000 times larger than their real size. a) Plastic clay. Water surrounds all the clay crystals and thesc can move easily. b) Leathcrhard clay. The clay crystals touch each other but there is still lubricating Water in the clay.

firebox mouth (fig . Z-132). All spyholes and vent holes are left open during smoking to let out the resulting steam before it condensesat colder spots of the setting. It must be emphasized: GO slow. The kiln will contain the result of weeks of hard work and it is very easyto ruin ii at this stage. Condensed water

The smoking period is ftished when the air coming out of the spyholes contains only a little or no moisture. This can be tested by holding a piece of glass which is of room temperature in the air stream above the spyhole. If water forms (condenses)immediately on the glasssmoking should be continued until only a little moisture is formed after holding the glassat the spyhole for a number of seconds. 114

c) Air-dried clay. All the lubricating water has evdporated and only pore wale: remains between the clay crystals. dl The pore water turned to steam inside the clay and caused the clay to crack becausethe clay was heated to above 100 “C too suddenly.

Fig. 2-132: The fire is in this casekept outside the firebox until the water smoking period is over.

Ceramic chnge

The temperature inside the kiln on completion of smoking should be 120-200 “C and then the real firing can start. The spyholes and vent hples should be closed, and the firing time, from the end of smoking until a dark red colour is visible inside the kiln, should take more than four hours. Between 350-700 “C a ceramic change takes place, which permanently changes the plastic clay into something rock-like that can never again be softened by water and formed into a pot. The clay particles contain water in their crystal structure (Al2 O3.2Si02 -2H20). This chemically bound water is released from the crystal structure and changes the crystals so that they cannot go back to their former shape. This chemically bound water amounts to 14% of bone-dry clay and its release will normally not cause the pots to crack. But the free silica or sand in the body expands suddenly at 573 “C and both actions combined may causeproblems. The ceramic change is at its peak around 600 “C. Chemi&y bound water from within the clay particles is dn;len out and often white stearn can’ bsl seen at the chimney at this point. If the firing goestoo fast, around 600 “C this rapid releaseof water may also cause the pots to crack.

A black core in a broken piece of a biscuitfired pot is a sign of’ unburned carbon. Top temperature

At around 800 “C the clay starts to harden. The clay hardens as soda, potash, lime and other impurities in the clay begin to melt, thereby glueing the clay particles together. This will give strength to the clay body and more so as the temperature rises. ?Gs process is called vitrification. Tradition‘4 pottery fired in pit kilns is only fired up to this temperature. Ceramic ware that is going to he glazed after a first firing is normally not fired higher than 900-1000 “C becausethe pots should remain porous for the application of glazes. Earthenware always has problems with crazing of its glazes.A higher biscuit tiring reduces the problem but also increases the danger of overfiring the biscuit ware. For such firings the top temperature should be judged by the help of cones (p. 120) or by drawing a test piece and checking its ability to absorb water. How.ever,normally the firemaster can judge when the desired biscuit temperature is reached by the colour inside the kiln. Stoking is then stopped and when the inside is clear of combustion gasesthe dampers are closed.

Burn-out

The carbon or vegetable matter in the clay will start to bum out when a red glow is reached, but the burning out will only be completed at around 900 “C. Clays containing a lot of carbon should be given a tiring with excessair from 800-900 “C. A fast biscuit firing may close the surface of the clay before all the carbon gets out. This may later cause blistering of the glaze and the clay may even bloat at higher temperaturesfrom zhe pressure of the trapped carbon gases.

The air intake of the fireboxes. spyholes and vent holes should be sealedcompletely after firing and the kiln left to cool by itself. It is tempting to speed up cooling, but if the kiln is cooled too fast pots may crack. The clay contracts suddenly at 573 “C and if the cooling is uneven it will causecracking. The free silica (quartz) of the clay changesits crystal shape suddenly at 573 “C. When heated free silica will expand and when it cools it shrinks again and this may causecracking of the pots during cooling. During firing this 115

However. when firing large pots it is prudent to slow down the firing around 573 “C. Apart from this the firing can proceed at a steady rate until the maturing temperature of the glaze is reached. Oxidizingjredrrcing

Fig. L-133: Firing is over and the Champaknngaitype kiln has been sealed.

expansion does not cause problems as the clay is still very open and has room for this movement. These cracks may not become obvious until after the glaze firing as they may be very fine. The crack pattern will often look like a brick wall. Remediesare: a) to cool more slowly, b) to raise biscuit temperature slightly, c) to decrease the amount of free silica (sand) or substitute it with fine grog. 2.7.2 Glaze firing If the ware has been biscuit-fired already there is no need for an extended water smoking, but the water from the glazing should be allowed to dry out slowly especially if the glaze shows a tendency to crawl. The glaze crawls away from rims or forms islands where the glaze has crawled away. This may be causedby firing the glazed pots before they havedried properly. The tiring rate would normally be lOO150 “C per hour’ . ____-I_ ’ F. Olsen, The Kiln Book, n, 131, describesfiring to cone 10 (1300 “C) in four hours without problems. This is possible wiih some clays provided highquality kiln slabs are used.

The mixture of gasesinside the kiln affects both the clay and the glazes. A firing with excess amount of air intake (oxygen) is called oxidizing and a firing with too little air for complete combustion of the fuel is called reducing. The main difference between these two firing conditions is the changeof colour in clay and ghazes.For example, the metal iron has a gray or black coiour but if it is exposed to air it turns to rust, which is red. Fig. 2-134: Steady stoking is needed to raise the temperature.

Rust is iron + oxygen or iron oxide and is present in most clays. A clay with a small iron oxide content will fire to a yellow‘or buff colour when the firing is kept oxidizing throughout, whereasit wilI turn to a grey colour if the fire is reducing. What happens Is that the reduction firing produces a ‘lot of half-burned carbon that has been starved of air. On its way through the kiln this carbon picks up the oxygen in the iron oxide and the “rust” is turned back to its original metal, iron, which is grey. It is more economical to keep a lightly oxidizing or neutral firing throughout as a reduction firing means that some fuel is .not being completely burned. If the special tiolour effect of a reduction firing is desired it should be done at the right time. For changing the colour of the glaze the reducing firing should be started at lOO-150 ‘C below the maturing temperature of the glaze, whereas for changing the colour of the body reduction will only be effective before the covering glazestarts to melt. The firing is kept oxidizing until the right temperature for reduction is reached. Reduction is then started by letting in less Gr.at the fireboxes and by partly closing the dampers. Reduction is in process when flames come out of the spyholes. However, a heavy reduction is not needed and is a waste of fuel. For ware that has not been biscuit-fired reduction should not be started before the temperature is above 1000 “C when all carbon in the clay has been allowed to bum out.

dition of the glazed ware inside the kiln. If the glaze surface is still rough the firing should be continued. From the look of the test piece the firemaster can judge when to draw the next test piece. It may be necessary to reduce or stop stoking while drawing and care should be taken to draw the tests quickly in order not to cool the kiln unnecessarily. Soaking

Tests should be drawn both from’ the top and bottom part of the setting. If the temperature is uneven the maturing temperature should be kept for one or two hours, allowing the glaze all over the kiln to melt properly. Such a period is called soaking. Cones A set with three different bending temperatures of cones can provide a warning so that when the first cone bends it indicates that there is only 30 “C to go before reaching maturing temperature. If, for example, the cone at the bottom ipyhole is not bending at the same time as the upper cone the firemaster can start stoking more slowly in order to allow the bottom temperature to catch up with the top. The maturing temperature is reached when the second cone bends. The last cone, with a bending temperature 30 “C above the maturing point, should not bend but gives the firemaster a warning in case the temperature should rise ’ during the soaking period.

Test draw Finishing

The firemaster should be able to judge the approximate temperature of the kiln by the colour of the glow inside. When this colour indicates that the maturing temperature is soon to be reacheda test piece from the kiln should be drawn using a crooked iron rod (p. 119). The glazed test piecewill show the con-

.

*

When the firemaster, from the look of test draws and cones, feels confident that the glazes have matured the firing can be stopped. The stoking of fuel is stopped and the dampers are left open until the inside of the kiln is clear of combustion gases. The 117

will have a sharp edge because at this low temperature the glaze had solidified when the body cracked. The problem occurs often with stoneware, which is fired to 1250-1300 “C. Saggarsand slabs may suffer even more because they have developed a higher content of crystobailite due to their many cycles of firings. Fig. 2-136: Teacups are cleaped and graded after being drawn from the kiln.

Fig. 2-135: Saggnrswith finished cupsare drawn from a hot kiln.

dampers are then closed completely and all spyholes and tirebox inlets are sealed. In case iron grates or drip-plate burners have been used their life will be prolonged if they are pulled out at this stage. If the firing has been reducing then a period of lo-20 minutes oxidizing at the end will brighten the glazeswithout changing the reduction effect on the colour of the glaze.

The kiln should be left to cool and only when the temperature is detinitely below 200 “C can the door be opened. The temperature is low enough if it is possible to hold an arm urside the kiln for a short while. Too sudden a cooling will not only damage the ware but also the kiln structure and the sag garsor kiln slabs. Above 1100 “C a lot of free silica is formed in the clay body. Much of it will take the form of a crystal called crystoballite, which shrinks 3% at 230 “C during cooling. This shrinkage will cause many pots to crack if cooling is too sudden. These cracks will be long clean cracks of the body and the glaze 118

Remediesare: a) slower cooling around 230 “C (and 573 “C), b) to reduce silica (sand) in the clay body by substituting grog, c) to add more feldspar to the clay body. The feldspar will fuse together with the free silica and crystobahite and the resulting glass will not havesudden shrinkagepoints. Ah potters are eagerto seethe result of their work but, if they cannot wait for the kiln to cool slowly, only broken pots may be the reward for their haste.

2.8, Temperature

the kiln, is seen at 470 “C but during daylight a red colour may not be seen before around 600 “C. The higher the temperature, the brighter the colour becomesas shown in the table. The experienced firemaster will be able to accurately judge the temperature by its colour. This skill is one of several additional sensesdeveloped during countless hours of tending firings and even a firemaster who is fortunate enough to have other more sophisticated measuring methods such as those described below should compare these with the colour reading before trusting them completely.

measurement

2.8.1 Thermometers

2.8.3 Test draw

The temperature inside the kiin cannot be measured with ordinary mercury-in-glass thermometers above 550 “C. Thermometers may still be useful for measuring temperatures during smoking and cooling periods and they can be used to read the temperature of the flue gasesin the chimney.

Glazed test pieces made from the same clay body and with the same glaze as the rest of the ware fued in the kiln can be used to judge when the glaze has matured. The test pieces should be placed close to the spyholes from where they can be drawn out with the help of an iron rod (fig. 2-138). When the colour indicates that the tiring is close to completion the firemaster draws a test piece and from the extent of fusion of the glaze the condition of the rest of the ware is revealed. The colour of the glaze though may differ from that of the finished ware. The test pieces can be shaped as rings (fig. 2-137) or can be small cups with a hole in the bottom for easy fetching.

2.8.2 Colour The colour inside the kiln is a good indicator of the temperature. The lowest visible red, which is visible only when it is dark outside Colour of temperature Lowest visible red, night-time Lowest visible red, daylight Dark red - cherry red Cherry red - bright cherry red Bright cherry red - orange Orange - yellow

Yellow - light yellow Light yellow - white White - bluish white

“C 470 550-650 650-750 750-815 815-900 900-1090 1090-1315 1315-1540 1540

Fig. 2-137: Two examples of glazed test pieces: a ring of clay and a cupwith its bottom pierced

119

2.8.4 Cones Cones are slim three-sidedpyramids 5-7 cm high and made from various mixtures ot kaolin, feldspar, quartz, limestone and other minerals. The cones soften like clay and glazes and bend depending on the melting point of the mixture they are made from. Commercial cones are available for measuring temperatures of 600--2000 “C within steps of about 20 “C. The cones have a printed number corresponding to their bending temperature (see table of cones in appendix). Set of three cones

Fig.

2-l

38:

wth the help

120

hWlnF

d test

LYlpttlrwgll

of nn iron rod

ttw

spytmie

Cones are normally used in a set of three placed in front of a spyhole from where the firemaster can see them during firing. In the example (fig. Z-139) where the maturing of the glaze corresponds to the bending of

Setting of cones

The cones should be set in a well grogged clay at a slight angle and with the flat side of the pyramid away from the bending direction. The firemaster should make sure that the cones are set in the sameway at each firing. They should not be placed too close to the spyhole, otherwise they will be cooled by air entering through the spyhole. Before firing the firemaster should look at the placement of the cones through the spyhole and remember their position for later. At temperatures above 1100 “C it can be very difficult to see the cones properly and one cone can easily be mistaken for another. It helps to watch the cones through a dark (smoked) piece of glassor through dark sunglasses. Heat-work

Cones do not really measure temperatures but rather heat-work or the combined effect of heat and time. If cone 7, for example, is heated at about 250 “C per hour it will bend at 1230 “C but if heated at 50 “C per hour it. may bend at only 1200 “C. Cones with the same number but from different factories may not bend at the same temperature and so before cones from a new supplier are used they should be fired in the kiln alongside the old cones to make sure that they bend at the sametime. Fig. 2-139: Settmg of cones a) Cones should he set similarly at each firing. h) Cone 6 has started to bend. warning the firemaster that the firing is soon to finish. c) (‘one ? is on Its WI) down. When the tip of the cone touches the bilse the maturing temperature has been reached.

cone 7 ( 1230 “C) another one. a cone 6 (100 “C), is placed in front of cone 7 so that the bending of cone 6 provides a warning. Behid Lone 7 a cone 8 is placed which shows whether the kiln is ovelfnred.

2.8.5 Pyrometer A pyrometer reads the temperature directly by measuring the electric current which is produced in a thermocouple. The thermocouple is made from two wires of different materials which are joined at one end. This end is inserted into the kiln chamber,where it is protected by a ceramic tube from corrosion (fig. Z-140). 121

and test draws do. Furthermore, a pyr. meter may fail.

Fig. Z-140: Pyrometer

2.8.6 Self-madecones

P

compensating wire

t

For temperatures up to 1100 “C the joined wires are made from 90% nickel f 10%chro. mium for the positive wire and 98% nickel + 2% aluminium for the negativewire. These metals are usually cheap but for temperatures up to 1500 “C the two wires need to be made from very expensive materials: platinum (negativewire) and 87%platinum + 13%rodium (positive wire). The wire leading from the thermocouple to the pyrometer is made from metals electrically similar to the ones used in the thermocouple and if ordinary wire is used the pyrometer will not be accurate. A pyrometer shows the actual temperature and is able to show the firemaster how fast the temperature is rising as well as the rate of cooling. It is a very helpful instrument but is expensiveand spareparts can be difficult to get. Therefore, its use in many countries will be limited to pottery training centres and bigger factories. Warrhg

A firing should never be measuredby a pyrometer only. The final judgement of when the firing is completed should still be based on cones or test draws. A pyrometer only shows the temperature and does not record the condition of clay and glazes as cones 122

Cones are made by a few large factories. These guarantee a consistent quality so that cones of the samenumber from the samefactory should bend simultaneously even if their years of manufacture are years apart This is only possiblewith a very strict control of raw materials and production. Even so, cones are inexpensive and so it would normally not make sense for potters to make cones themselves.However, in many remote areas, or where overseasimports are diffcult, cones are often not available and potters could produce them in their own workshop. Cone body

It takes patience to find the right mixture of clay, sand and melters (fluxes) which will bend at the desired temperature. The first problem is to get raw materials that do not differ much from batch to batch. Clay

A pure kaolin clay which should contain the same proportion of sand and clay with each batch is the most reliable. Alternatively a stoneware clay or the plastic production clay of the workshop can be used. Clay with a high iron content is lesssuitable becausethe iron oxide acts as a melter in a reduction firing but not so in an oxidizing firing. Silk0

Silica sand or quartz is needed for adjusting the bending or softening temperature. The more silica, the higher is the bending temperature. The sand particles also help to open

up the cone mixture so that it is less likely to crack during drying. Melters Melters (fluxes) which lower the bending temperature are added to the mixture of clay and sand. Melters such as feldspar, whiting (or limestone) and talc are sufficient for the higher temperatures above 1200 “C. Below that, melters such as borax or boric acid are added. Potashand soda can replace these if they arc not available.P\)tash,soda, borax and boric acid are all soluble in water. When these materials are added directly to a moist cone body they will to. some degree leach out of the cone body and settle on the surface of the cones. This will cause the cones to bend at higher temperatures than intended. The materials could be made insoluble by melting them together with the silica sand, feldspar, whiting and talc of the colic body and then, after crushing the resulting glass to a fine powder, adding this to the clay. That is a laborious processand a simpler method would be to mix and form the cones in a semi-dry state by adding a glue such as starch or gum arabic. C0t1.cmiuntres

There are many factors determining the melting point of a ceramic mixture besides the proportion of the various materials in the mixture. Therefore, the cone body recipes given next column are only meant as a starting point for further experimenting. Kaolin, whiting (limestone, chalk), talc and feldspar all contain silica in varying degrees. One kaolin clay may be very pure while another source may contain high amounts of silica sand. These recipes are based on pure kaolin while the recipesusing stoneware clay have smaller amounts of silica sand in them to compensate for the sand in the stoneware clay.

Cone USa, iOO0 “C

Potash feldspar Talc Kaolin Quartz, silica sand Whiting Borax

10 6 22 20 8 34

Potash feldspar Talc Stoneware clay Quartz, silica sand Whiting Borax

8 6 29 16 8 33

Cone la, I1 00 “C Potash feldspar Talc Kaolin Quartz, silica sand Whiting Borax

18 3 22 32 10 15

Potash feldspar Talc Stoneware clay Quartz, silica sand Whiting Borax

19 2 27 27 10 15

Cone 7,1230 “C Potash feldspar Kaolin Quartz, silica sand Whiting Potash feldspar Stoneware clay Quartz, silica sand Whiting All recipes by weight.

A simpler solution is to make the cones from a mixture of the clay and the glaze used in the workshop. Example of a mi..ture for cone 8,1X0 ‘C: 22 stoneware clay glaze for 1250 “C 51 27 silica sand (the glaze recipe: 4 feldspar, 3 quartz, 2 whiting, 1 kaolin) Experimen ring

A seriesof mixtures has to be tested before the right bending temperature is arrived at. The simplest way is to start with the recipes given above and vary the amount of clay and silica sand in, say, three steps of 5%. Cones of these three different mixtures are then fired in a normal production firing and through :he spyhole an eye is kept on the bending of the cones. The bending is then compared with either the bending of commercial cones fired along with the self-made ones or with the state of the glaze on draw tests. In case none of the cones bend, new mixtures should be made with lessclay and silica sand but if the cones bend too soon more clay and silica sand should be added. The test mixtures should be prepared as described and it is important to use the same raw materials and the same procedures during testing and also later when the actual cones are produced. Preparation oj*cone miuures

The clay, sand, feldspar, limestoneor whiting should be sampled so that later, when a new batch of cones is to be made. it will be possible to obtain raw materials of similar quality. In all deposits of raw materials there will be a variation in particle size, sand content, etc. This variation can be reduced by taking samples from many different places in the deposit and mixing thesethoroughly. A much 1’4

bigger portion than needed is collected and the amount required is divided from this by quartering (see testing, p. 39). All the materials are dried and screened(100 mesh) before weighing out the different amounts according to the recipe. This should be done before experimenting so that the same materials can be used for testing and production. After the materials are weighed they are mixed well and sieved(100 mesh) again. About 6 g material is neededfor one cone. Shaphg of wnes

The cone mixture is easier to shape if a starch or glue is added to the dry mixture together with water. If borax is used, the water content must be kept low. All cones must be of exactly the sameshape.A mould is made of plaster, hardwood or iron according to the dimensions shown in fig. 2-141. The cones are three-sided pyramids with a triangular base. The base is cut so that it facilitates a setting angle of 70” with the horizontal. To begin with, only a few cones are made and tested so that if these cones do not bend at the right time the rest of the mixture can be adjusted. Fig. 2-141: Shape and dimension of cones

Biscuit

Then the whole mixture is shapedinto cones and dried. If an organic glue such as starch or sugar syrup has been used it will with time go rotten, stink terribly and the cone made with it may be easily broken when handled. To prevent these problems the cones could be given a low temperature biscuit firing, ensuring they are all fired at the same time and at the same place in the kiln. However, it should be noted that a biscuit firing will slightly lower the final bending temperature of the cones. Cones which are bonded by an artificial glue can be stored without biscuiting. New hatch

Once the right mixture is establishedcones are easy to make. So it pays to make enough for several years of firings. Five hundred cones of about 6 g could be made from 3 kg of raw materials. Note down carefully how the cones are made and from which materials

so that when the first batch is finished a new batch of conesof the samebending temperature can be made. Remember that with cones it is important to expose them to the same conditions at each firing; setting should be at the same distance from spyholes and at the same angle. A new batch of cones should be made well in advance of finishing the old ones so that the bending temperature of the new cones can be tested in the kiln alongside the old cones.

Use of‘ self-made cones

Self-made cones will not be as reliable as good-quality commercial comesand so test draws of glazed pieces should also be done. The cones will help to give the firemaster a warning of when to draw tests. They can also be placed at the top and bottom or front and back of the setting so that the firemaster can change the damper setting or slow the firing rate to compensatefor temperature differenceswithin the kiln chamber.

i2.5

Appendix

Tables of weights and measures Metric system: 1 kilometre, km

-

lm 1 cm 1 mm

= 100 centimetres, cm 10 millimetres, mm = = 1000 micron, ,u

to convert: -..--.-..ltwgth. m m cm mm

~.. -. -~.----

1000 metres, m

to:

multiply metric by: -.--.-- .---~.---- --... -_-._-_-___.-__ feet 3.280 inches 39.370 inches .394 inches .039 -. -.-- ____-..____ ------.--

1 cubic mctre, m3 11 1 ml

= 1000 litres, i = 1000 cm3 or ml = 1000 mm3

1 ton 1 kg lg

= 1000 kilograms, kg = 1000 grams.g = 1000 milligrams, mg

to convert:

to:

multiply UK & US by: ---

---_-__ feet m m Inches cm inches mm inches -- ..-..- -... - .._.-._-----.-

.3os .025 2.54 25.400 _-..-.-. .___..._._..

.-

area:

hectare mz cm?

axes sq. feet sq. inches --.~.._--

2.471 10.764 .I55 ..--_.-___-_

acres sq. feet sq. inches -------

35.314 .276 XI61 61.020 .219 ,264

cm feet cord cu. inches cu. inches

hectare td

cm2 .-..-.-I--

.405 .093 6.451 -----. --- ...______

wohcmne. $

cm3 (cc) 1 1 1

cu. feet cord (wood) cu. inches cu.

inches

I1.K gallon U.S gallon

U.K gall011

U.S gallon ___._---___ ---.

m3 m3 cm3 (cc) I 1

I .--- _---.--.------.-.-

0.0283 3.625 16.387 .O16 4.546 3.785

weight

kilograms grams -. --__ 126

pounds ounces

2.205 0.035

pounds ounces

kilograms grams

.453 28.349

_________

Table of sieve mesh sizes

The fineness of a sieveis measured as the number of threads that can be counted acrossone inch of sievemesh. A number (63, 80, 100 . . .) followed by “mesh” indicates the finenessof sieves. The numbers in the first column correspond to threads per inch (2.54 cm) of sieve mesh according to British standard series.The second and third column show the maximum particle site, in mm and inch, that can passthrough the sievemesh. B.S.S. number

size in mm

5

3.355 2.812 2.410 2.057 I.676 1.404 1.203 1.003 0.853 0.699 0.600 0.500 0.422 0.353 0.295 0.25 1 0.211 0.178 0.152 0.124 0.104 0.089 0.076 0.053 0.043

6 7 8

10 12 14 16 18 22 2s 30 36 44 52 60 12 85 100 120 150 170 200 300 350 -

size in

inch 0.1320 0.1107 0.0949 0.0810 0.0660 0.0553 0.0474 0.0395 0.0336 0.0275 0.0236 0.0197 0.0166 0.0139 0.0116 0.0099 0.0083 0.0070 0.0060 0.0049 0.004 I 0.0035 0.0030 0.002 1 0.0017 I_-

Table of geological particle grading (Wentworth-Udden Scale) Particle -__-_-. Boulder Cobble Pebble Gravel (granule) Sand Silt Clay

Size range above 256 mm 64-256 mm 4-64 mm Z--4 mm l/16 -2 mm l/256-1/16 mm below l/256 mm

127

ii

Table of Orton cones

Table of Seger cones German, Staffordshire, French Cone No.

New “H” series Staffordshire Cone No.

“C

“F

600 625 650 670 690

1112 1157 1202 1238 1274

022 021 020 019

H 022 H022A H 021 H 020 H 019

1100 1110 1120 1130 1140

2012 2030 2048 2066 2084

710 730 750 790 815

1310 1346 1382 1454 1499

018 017 016 015 014 a

HO18 HO17 H 016 H 015 HO14

1150 1160 1170 1180 1190

2102 2120 2138 2156 2174

835 855 880 900 920

1535 1571 1616 1652 1688

013 a 012a 011 a 010 a 09 a

HO13 H 012 HO11 H 010 H 09

1200 1215 1230 1240 1250

2192 2219 2246 2264 2282

H 08 HO7 H07A H 06 H 06 A

1260 1270 1280 1290 1300

2300 2318 2336 2354 2372

13

H8A H8B H9 H9A H 10

H 05 HO5 A H 04 H 04 A HO3

1310 1320 1350 1380 1410

2390 2408 2462 2516 2570

11 12 13 14

H 10-4 Hll H 12 H 13 H 14

H 03 A H 02 HO2 A HO1 HO1 A

1435 1460 1480 is00 1520

2615 2660 2696 2732 2768

1.5 16 17 18 19

H 15 H 16 H17 H 18 H 19

940 960 970 980 990

1724 1760 1778 1796 1814

08 a 07 a

1000 JO10 1020 1030 1040

1832 1850 1868 1886 1904

05 a

1050 1060 1070 1080 1090

1922 1940 1958 1976 1994

06 a

04 a 03 a 02 a 01 a

Germau. Staffordshire, French Cone No.

New “H” series Staffordshire Cone No.

OF

“c

Hl HlA H2 H2A H3

la 2a 3a

H3A H4 ‘H4A HS H5A

4a 5a

H6 H6A H7 H7A H8

6a 7 8

9

’

(United States, Ohio, The E. Orton Jr. Ceramic Foundation) Bending temperatures of large cones whep heated at lSO”/hour “C

“F

Cone No.

“C

“F

Cone No.

600 614 635 683 717

1112 1137 1175 1261 1323

022 021 020 019 018

1120 1137 1154 1162 1168

2048 2079 2109 2124 2134

02 01 1 2 ‘3

747 792 804 838 852

1377 1458 1479 1540 1566

017 016 015 014 013

1186 1196 1222 1240 1263

2167 2185 2232 2264 2305

4 5 6 7 8

884 894 894 923 955

1623 1641 1641 1693 1751

012 011 010 09 08

1280 1305 1315 1326 1346

2336 2381 2399 2419 2455

9 10 11 12 13

984 999 1046 1060 1101

1803 1830 1915 1940 2014

07 06 05 04 03

1366 1431 1473 1485 1506

2491 2608 2683 1705 2743

14 15 16 17 18

---

-

Note: The temperatures indicated in these cone tables may not be the same as when the cones bend in the individual potter’s kiln. Cones are not used for measuring temperatures but for indicating the condition of clay and @ares.